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General Laboratory: Lean Spaghetti Mapping Online Training

A Spaghetti map is a tool that uses a continuous line to trace the path of a tube through all phases of the laboratory process. Spaghetti diagrams expose inefficient layouts and large distances traveled between steps.

Welcome to the Lean Spaghetti Mapping Online Training course.  The Keen but not Lean Medical Center (KLMC) Laboratory is continuing their investment into their Lean Team.  They are now taking a closer look at how people and tubes move from the pre-analytical to the analytical area using spaghetti mapping to eliminate non value added activities and improve the flow of their process. Join the KLMC team on their journey and learn how to apply this tool in your laboratory.   Select Next to continue.   Define spaghetti mapping Describe how to map the current process Describe how to redefine a process using spaghetti mapping Identify the key steps when recording motion to create a spaghetti map Upon successful completion of this course, you will be able to: Select Next to continue. Congratulations.  You have completed the Lean Spaghetti Mapping Online Training course.  Listed below are key points that have been presented.  Take time to review the material before you proceed to the final quiz.  Define Spaghetti Mapping What is a Spaghetti Map? A Spaghetti Map is a tool that uses a continuous line to trace the path of a tube through all phases of the laboratory process. Spaghetti diagrams expose inefficient layouts and large distances traveled between steps. Key steps of Spaghetti Mapping include the following: Create or obtain a current floor plan with all equipment marked on it. Record the motion in an area by following the current state work process. Draw the path on the floor layout. Note any safety or ergonomic hazards. Describe the current state and the total distance traveled. Explore ways that the total distance travelled could be reduced. Move equipment. Bring materials closer to the workplace. Eliminate rework steps. Potentially change the order of steps. Describe how to map the current process The first step in Spaghetti Mapping is to obtain a scale drawing of the area being investigated. When creating this drawing: An alternative to a hand drawing is a scaled floor plan using Visio or another software drawing package. Ensure that it is accurate and contains all analyzers and equipment. Note the time, date and process being evaluated, but not the name of the individuals. Explain to the team what's being done and ask for volunteers. Identify the key steps when recording motion to create a Spaghetti Map The next step in Spaghetti Mapping is to record all the motion in the area as tubes travel through the process. Trace the actual steps taken while tubes and forms are moving through the departments. Note any stops with sequential numbers and mark the time for each stop. Note any awkward elements in the line taken. Mark any inherent interruptions in the path - such as transferring tubes to a centrifuge or analyzer racks. Note why certain trips are made - for example, getting necessary supplies or signatures. Measure the furthest distances traveled and note the highest activity points. Review the map with the operators/owners to obtain feedback and agreement. Describe how to redefine a process using Spaghetti Mapping Key steps to redefining the process include:  Identify areas of high activity. Identify areas of prolonged distance traveled. Identify any areas where the direction of flow is interrupted or stopped. Select Next to continue. What is a Spaghetti map? A Spaghetti map is a tool that uses a continuous line to trace the path of a tube through all phases of the laboratory process. Spaghetti diagrams expose inefficient layouts and large distances traveled between steps. Key steps of Spaghetti Mapping include the following: Create or obtain a current floor plan, including all equipment Record the motion in an area by following the current state work process Draw the path on the floor layout Note any safety or ergonomic hazards Describe the current state and the total distance traveled Explore ways that the total distance travelled could be reduced Move equipment Bring materials closer to the workplace Eliminating rework steps Potentially change the order of steps Spaghetti Mapping Learn more about spaghetti mapping. Slide NumberText BlocksCalloutsAudio ScriptImage File1 Benefits of Spaghetti Mapping Helps to identify areas where time can be saved by visualizing unnecessary movement of tubes, staff or consumables The time saved can be used differently and therefore can help to reduce delays and be used to improve patient care. Can identify some of the sources of problems and communicate where there is waste in your process, and help decide on the next steps to take     Select Next to continue.   Note: If audio does not automatically start, select the play arrow in the top left to begin.The spaghetti mapping tool helps you identify areas where time can be saved by visualizing unnecessary movement of tubes, staff or consumables. The time saved can be used differently and therefore can help to reduce delays and be used to improve patient care. Creating a spaghetti map can also identify some of the sources of problems and communicate where there is waste in your process. This can help you decide on the next steps to take. For example, you may use the diagram to make changes in the layout of the department to improve efficiency of departmental flows. Select next to continue. 2 When does Spaghetti Mapping work best? The ideas must be supported by upper management. The team needs to be prepared to change the ways things were done in the past. The team leaders need to prove why change is necessary and what the goal is at the end. It is important that the team have autonomy, available resources, and pride in workmanship.     Select Next to continue.   In order to make a fundamental improvement to the spaghetti map process outcome, new ideas must be supported by upper management. Doing things the same way yields the same results. Prepare to change the ways things were done in the past. The team leaders need to prove why change is necessary and identify the end goal. It's important that the team have autonomy, available resources, and pride of workmanship. Select next to continue.3 Tracking Flow    Spaghetti maps can be used to track: Product Flow Paper Flow People Flow Creating a spaghetti diagram is the visual creation of actual flow, not what it should be or perceived to be. It is a snapshot in time so it may not include all what-if and special scenarios, but these do warrant discussion as the team progresses.   Because of this, spaghetti diagrams are best used in conjunction with other tools and techniques that help build a visual picture of the workings of a department, for example, process mapping.         Select Next to continue. Spaghetti maps can be used to track product flow, paper flow, and people flow. When tracking multiple types of flow, it's a good idea to use a different line type or color for each flow type, or use a separate map for each flow path for more clarity. Creating a spaghetti diagram is the visual creation of actual flow. The keyword is ACTUAL, not what it should be or is perceived to be. It's a snapshot in time, so it may not include all possibilities or special scenarios. However, these situations do warrant discussion as the team progresses. Therefore, spaghetti diagrams are best used in conjunction with other tools and techniques that help build a visual picture of the workings of a department, for example, process mapping. Select Next to continue.4 This is not an exercise to do on a computer at a desk. Creating a spaghetti map diagram should be done with or by the operators or those that use the process. Record the path with a pencil and use a measuring wheel or tape measure to document distances. You are looking for "cooked spaghetti", not spaghetti directly from the box; things rarely move in straight lines. When complete, select the X in the upper-right corner to close the window and continue.Creating a spaghetti map is not an exercise to do on a computer at a desk. The work should be done with or by the operators or those that use the process. Record the path with a pencil and use a measuring wheel or tape measure to document distances. The map should end up looking more like "cooked spaghetti", not spaghetti directly from the box, since things rarely move in straight lines. When complete, select the X in the upper-right corner to close the window and continue. The operator’s control and display of the DFM Tube Stand includes controls that are keyed to 9 different features or functions. Some of which include longitudinal and transverse lock releases as well as longitudinal and transverse detent indicators. Click the icon below to view descriptions of all of the features. The first step in spaghetti mapping is to obtain a scale drawing of the area being investigated. When creating this drawing: An alternative to a hand drawing is a scaled floor plan using Visio or another software drawing package. Ensure that it is accurate and contains all analyzers and equipment. Note the time, date and process being evaluated, but not the names of the individuals. Explain to the team what's being done and ask for volunteers. Select Next to continue. Key steps to redefining the process include: Identifying areas of high activity Identifying areas of prolonged distance traveled Identify any areas where the direction of flow is interrupted or stopped Redefining the Process See the newly redefined process at KLMC. The KLMC team used the spaghetti maps to identify a couple of areas where they could improve traffic flow in the pre-analytical area: Move the centrifuges in the pre-analytical area to reduce travel.  The centrifuges were in a separate room 15 meters from the sorting bench.  The team moved them to reduce the travel distance from 15 to 5 meters. With 20 journeys a day, this equates to a reduction in travel of 200 meters a day, and with 260 normal working days, this is an annual savings of 52 kilometers (or 32.5 miles). This is an example of Extra Motion waste. The KLMC team also noted that the pneumatic tube system was inconveniently placed and initiated a request to move the system to a better location. When complete, select the X in the upper-right corner to close the window and continue. Receiving Area-post Lean Product Handled=7 times Product Traveled=14 meters (5m to and from centrifuge)   Processing Desk   Centrifuge   Ready for Loading   Aliquot   Decapper   Spun Samples Additional Considerations Learn about some additional considerations in redefining the process. Additional factors that should be considered when redefining the process using spaghetti mapping: It may take several iterations before the final layout is determined. The operators will also generate ideas which should be considered and evaluated. Using Lean principles the changes should be executed with as little cost and the best quality possible. Some items may require capital investment or rely on other parties such as Facilities or instrument vendors which will require senior management approval. These should be investigated and submitted if justifiable. Make a note of these outstanding action items with timelines to the project checklist but don't allow them to stall progress. Put any open action items on an easel or board in the specific area and keep it visible for everyone to see. It is a good idea to audit the changes, especially until new habits are embedded and the culture is ingrained.   When complete, select the X in the upper-right corner to close the window and continue. The next step in spaghetti mapping is to record all the motion in the area as tubes travel through the process. Trace the actual steps taken while tubes and forms are moving through the departments. Note any stops with sequential numbers and mark the time for each stop. Note any awkward elements in the line taken. Mark any inherent interruptions in the path - such as transferring tubes to a centrifuge or analyzer racks. Note why certain trips are made - for example, getting necessary supplies or signatures. Measure the furthest distances traveled and note the highest activity points. Review the map with the operators/owners to obtain feedback and agreement. Select Next to continue.