Lean manufacturing, Lean thinking, Lean culture...

What is Lean?

Lean is typically associated with waste minimization, continuous improvement and respect for people. All of these measures contribute to more productive and efficient processes. Lean manufacturing is modelled on the Toyota Production System (TPS).

A leaner laboratory can make significant improvement in routine testing and analyses. Lean is already widely adopted to the manufacturing industry where many processes have benefited from continuous improvement projects. The laboratory is no exception! Whether it’s a clinical, diagnostic, analytical, quality control or microbiology lab, a lean lab will result in: 

         

• Enhanced productivity
• Reduced waste (muda)
• Increased throughput
• Faster turnaround times (TAT) 
• Significant cost reductions!
• Better employee morale

   

5 Lean Principles 

1. Value: define what is of value to the customer
2. Value Stream: identify the value stream, eliminate waste
3. Flow: Create a constant flow
4. Pull: Produce on demand
5. Perfection: Continuous improvement

Continuous Improvement - Kaizen

By adopting a Lean culture, laboratory processes can be improved significantly. Identifying and eliminating waste can really reduce costs. When the lab and processes are optimized in the Lean Six Sigma way, lab life is made a lot simpler and more productive. The Lean culture has a strong emphasis on respect for people – continuous improvement relies on this attribute. The lean culture values the process owners - i.e. lab technicians, scientists, supervisors etc. and has a policy of empowerment, each individual is responsible and engaged in a team effort to ensure continuous improvement or Kaizen. A lean lab should be an enhanced and more simplified productive environment with the added advantage of boosting morale.

Principles of Kaizen

Lean Six Sigma in the Laboratory

Lean manufacturing to Lean analysis - extending the potential of Lean Six Sigma in biopharmacutical industry

This blog is designed to introduce the concepts and techniques of continuous improvement in laboratory work spaces using Lean Six Sigma tools and techniques to create an efficient and productive. Lean Six sigma is a well established tool in manufacturing and it is gaining imminence in health care and services industries also. Lean Six Sigma can be applied to any project or any facility to improve efficiency by reducing waste, minimizing defects and adopting a philosophy of continuous improvement. In this blog, I will address the benefits of implementing lean six sigma in the laboratory. Lean is not a new concept in the biopharmaceutical industry, as it is adopted by most high profile biomanufacturing companies including Johnson and Johnson, Pfizer, Abbott, Baxter. The practical applications are not merely confined to the production area, it is a culture and methodology that is adopted throughout the industry. This blog will highlight the benefits of Lean Six Sigma in the QC laboratory and explores the tools and techniques that can be used to improve workflow efficiency and create a leaner, more productive quality laboratory.

Lean Six Sigma in biopharmaceutical QC laboratories creates efficient and productive workflow, reduces waste and increases sampling throughput.