CROPIA Project - 1 2008 IIE ANNUAL CONFERENCE & EXPO forums.pmcorp.com NEW! Project Scope Evaluated (by on-site observations and intervention)

CROPIA Project - CROPIA Project - 11

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2008 IIE ANNUAL CONFERENCE & EXPO

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Project Scope

Evaluated (by on-site observations and intervention) the routine day-to-day activities of the medical laboratory

Provided recommendations on modifications to the operational processes, procedures, and policies to optimize the workflow, performance, and overall customer (both internal and external) satisfaction with the courier

Optimized all courier routes using Arc Logistics® route optimization software to facilitate bringing in work (specimens) earlier in the workday

Gained analytical insights into the impact of the optimal solution on the overall system using Enterprise Dynamics® simulation software


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Observations

At initiation of the project, the following conditions existed: Total courier vehicles: 15 Total FTEs: 15 Total courier routes per day: 10 + local run Courier routing automation deployed: Hand-written route

sheets High specimen processing costs (overtime) due to

unbalanced arrival rate of specimens

Number of requisitions processed: 1000–1100 per day

Several high volume specimen receipt time frames during AM, PM and Night Shifts ~11:30 AM, ~2:00-5:00 PM, and ~10:00 PM


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Observations

Non-optimal work load leveling required the use of a midnight shift and overtime

Utilization of Medical Technologists (MTs) was not uniform across different shifts due to non-optimal work load leveling

Non-uniform utilizations of MTs made it difficult to optimize the shift schedule and avoid overtime

Specimen processing staff have limited workstations

Approximately 30-45 minutes of courier time is wasted between specimen drop-off and route continuation


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Observations

Lack of visual signaling resulted in the delay in retrieval of specimens from the ballroom area by pre-processing technicians (visual management)

Specimen testing procedures were not standardized For example: Grouping specimens by Tests or by Clients

Stability of Gajema Handhelds hampered the courier efficiency


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Agenda

Introduction to PMC

Project Scope

Observations

Process Improvement Methodology

Route Optimization Model

Simulation Model

Results and Recommendations

Questions and Discussion


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PMC consultants spent 2.5 days on site to map the current value stream

Primary areas reviewed included: specimen processing, couriers and technical departments

Value Stream Mapping was utilized to illustrate the current process flow graphically

This was accomplished with a cross-functional client team


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Data collected was brought back to PMC for analysis

Captured data entered into Arc Logistics® route optimization application

Route Optimization solution for load leveling was finalized after several iterations

Data collected from technical departments translated into Enterprise Dynamics® simulation modeling tool to analyze the effects of load leveling


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Simulation model output validated by PMC/client team

Validated model results confirmed that the night shift can be eliminated if perfect load leveling is achieved

New courier routes reviewed and validated by PMC/client team

In some cases, adjustments made for specimen pickups

Data for optimal courier routes was validated by actual observations


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Agenda

Introduction to PMC

Project Scope

Observations



Simulation Model




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Screenshot of “Map View”


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Screenshot of “Time View”


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Agenda

Introduction to PMC

Project Scope

Observations



Simulation Model




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Simulation Model

OBTAIN SPECIMENS PRE-PROCESSING

CHEMISTRY LAB

HEMATOLOGY LAB

MICROBIOLOGY LAB

SEROLOGY LAB

COURIER TEAM

Big Picture

SEROLOGISTS

MICROBIOLOGISTS

HEMATOLOGISTS

CHEMISTS


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Simulation Model

SPECIMEN ARRIVESOPERATORPROCESSESSPECIMEN

SPECIMEN DELAYEDIN LABORATORY

Laboratory

OPERATORMISC. TIME


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Simulation Model

Courier routes are black-boxed (schedules are based on actual trip times)

Weekends are not modeled

Operator walk times and lunch breaks are not considered

In order to prevent blocking, the following is assumed Infinite buffers between each department Infinite capacities for laboratory testing equipment


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Simulation Model


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Simulation Model

Model screenshot (2-dimensional)


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Simulation Model

Model screenshot (3-dimensional)


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Simulation Model

Base scenario

Load leveling scenario


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Agenda

Introduction to PMC

Project Scope

Observations



Simulation Model




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Optimization of initial routes revealed that the traditional routes would allow for the re-allocation of 2 couriers

Historical data analysis revealed that inflow of specimens based on the traditional routes had multiple spikes and thus required work load leveling The work load leveling achieved, as a result of optimized routes, helped the client to eliminate the night shift and improve the utilization of its morning shift medical technologists using simulation

Route optimization and subsequent work load leveling resulted in the reduction of 2 MT FTE resources (approximately $110,000 savings per year)


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It is also recommended that one of the re-allocated couriers be used as a runner who would retrieve specimens along with Gajema handhelds from other couriers returning to the site. This would result in savings of approximately

30-45 minutes of time which would otherwise be considered non-value- added activity

This would increase the availability of couriers for further improvement in work load leveling

To maintain optimum load leveling, courier routes should be re-optimized if there are changes/additions in the number of specimens and/or customer pick-up points


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Agenda

Introduction to PMC

Project Scope

Observations



Simulation Model




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Questions & Discussion

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Documents

CROPIA Project - 1 2008 IIE ANNUAL CONFERENCE & EXPO forums.pmcorp.com NEW! Project Scope Evaluated (by on-site observations and intervention)