Process Improvement Techniques Research Articles

Diagnosing patient flow issues in the emergency department: an Australasian hospital case study

PurposeThis study investigates how a hospital can increase the flow of patients through its emergency department by using benchmarking and process improvement techniques borrowed from the manufacturing sector.Design/methodology/approachAn in-depth case study of an Australasian public hospital utilises rigorous, multi-method data collection procedures with systems thinking to benchmark an emergency department (ED) value stream and identify the performance inhibitors.FindingsHigh levels of value stream uncertainty result from inefficient processes and weak controls. Reduced patient flow arises from senior management’s commitment to simplistic government targets, clinical staff that lack basic operations management skills, and fragmented information systems. High junior/senior staff ratios aggravate the lack of inter-functional integration and poor use of time and material resources, increasing the risk of a critical patient incident.Research limitations/implicationsThis research is limited to a single case; hence, further research should assess value stream maturity and associated performance enablers and inhibitors in other emergency departments experiencing patient flow delays.Practical implicationsThis study illustrates how hospital managers can use systems thinking and a context-free performance benchmarking measure to identify needed interventions and transferable best practices for achieving seamless patient flow.Originality/valueThis study is the first to operationalise the theoretical concept of the seamless healthcare system to acute care as defined by Parnaby and Towill (2008). It is also the first to use the uncertainty circle model in an Australasian public healthcare setting to objectively benchmark an emergency department's value stream maturity.

WIME Systematic Innovation Method based on 6WHI and Total Factor Matrix Analysis

The involved object of systematic innovation and management is neither a single goal nor a single meth-od. Firstly, the research object is a systematic and organic whole composed of multiple node elements with a certain degree of correlation. Secondly, the research method is multi-dimensional, comprehensive, all round and highly efficient. Innovation should break through the existing thinking framework, change the existing structure, add new components, give new energy and produce new functions. The 5W1H is a questioning approach and a problem-solving method that answers all the basic elements within a problem which are what, who, when, where, why, and how. It aims to view ideas from various perspectives and gain an in-depth understanding of a specific situation. On the basis of 5W1H analysis method, this paper puts forward the 6WHI systematic innovation management method, which increases the query words weather and if of the innovation expansion solution, increases the number of questions from 6 to 8, and expands innovative forward-looking and innovative solutions diversity, with smoother pronunciation, more exciting storm. Furthermore, a systematic innovation method based on 6WHI and total factor analysis is established, and a more general and normative model WIME method is presented. This method can be utilized as a continuous process-improvement technique in an organization. Taking the 17 letters of “if question patents” as the prefix, they are just 17 common key elements in system management and innovation. For each element mentioned above, 8 questions and answers of 6WHI are given to realize systematic management and innovation. The above two types of work are arranged according to the matrix format, and then the weighted evaluation method is introduced to evaluate the above management and innovation work, so as to give a general and standardized systematic management and innovation (WIME) method.

Kaizen-mindfulness a twin continuous improvement approach at workplace: A qualitative exploratory study

PurposeWorld Health Organizations (WHO) (2023) states that governments and employers have a responsibility to uphold that right by providing work that simultaneously prevents workers from experiencing excessive stress and mental health risks. The business environment continues to produce a lot of stress on workers, which includes internal pressures to achieve results and employees suffer the consequences. Some companies have turned to mindfulness as a technique that helps mitigate these consequences and have joined Kaizen as a process improvement technique in the work environment. Therefore, this study has a research purpose: “to comprehend the possible linkage between Kaizen philosophy from an individual perspective, with Mindfulness ZEN Buddhism technique to understand the individual benefit (well-being) of each employee in organizations.” The answer to this represents the research gap in this article. The research questions governing this study are as follows: RQ1: Does Mindfulness is used as Kaizen technique of personal-individual improvement in 21st-century organizations? RQ2: What elements and characteristics of Kaizen and mindfulness can be found working together? And RQ3: Which qualitative impact of mindfulness and Kaizen in the workplace outcome (well-being, performance of the job (process)) and relationships with other employees)?Design/methodology/approachThis research used a qualitative approach due to the recent phenomenon studied. In a certain way, it was used a mixed-method (combination of qualitative data – web search secondary data analysis and qualitative research-Convergence Model). First, it was done an intensive web search with the aim to identify companies' corporate mindfulness programs, along with companies which have applied mindfulness and Kaizen programs. It was identified a group of big companies with global and international presence (“famous” for their products and services) in diverse industrial and service sectors, country of origin and business locations; with the purpose of getting a holistic vision of all organizations which have practice Kaizen and mindfulness. Therefore, this study explored secondary data related to both practices, analyzing reports or briefings published in management magazines and official WEB pages and/or business magazines.FindingsAs a result of the triangulation of the data with its secondary data convergence model and qualitative research, a theoretical framework was reached that shows the benefits of the two combined twin techniques of Kaizen and mindfulness. The worker experiences a path that goes from concentrating on the execution of their processes, following their operating standards (Standardize, Do, Check, Act [SDCA] cycle), going through the evolution to continuous improvement or Plan-Do-Check-Act (PDCA) cycle, experiencing work with concentration-awareness and reducing your daily stress, maintaining high sensitivity to the work process and your environment and finally, discovering an essential life purpose. Finally, worker experiences benefit when there is wide application of both with the SDCA and PDCA cycles such as high motivation, constant learning from your mistakes, day-to-day learning and the Munen Musso (not using the mind).Research limitations/implicationsThe main limitation is the qualitative methodological bias and secondary data research. In addition, to have a theoretical sample. However, the richness of the data helps to overcome this limitation. On the other hand, the qualitative research interviews are for a certain geographical area, therefore, the results cannot be generalized.Practical implicationsThe results of this research can shed light on operations managers in the use of techniques for continuous improvement and improvement of people's quality of life, such as mindfulness. In Mexico, they are beginning to be used jointly (twin techniques) to comply with Regulation 035 of psychosocial risk, the researchers are sure that in other countries it will be used in the same way to comply with regulations. However, the research findings show the benefits that can be provided to workers in organizations by applying Kaizen and Mindfulness together.Originality/valueTo the best of the authors’ knowledge, according to the literature review, this is the first article that explores the relationship between Kaizen and Mindfulness as twin techniques that help improve the individual quality of life of employees in organizations.

A composite algorithm of lithography process in AlGaN/GaN-on-SiC HEMTs manufacturing

Manufacturing SiC-based GaN HEMT devices is challenging due to limited process windows, which results in low process yields and high costs. In this paper, process improvement techniques have been proposed by using a composite algorithm to address the issue of wafer-level CD non-uniformity in the lithography process. This algorithm is composed of a compensation module and a classification module. The compensation module corrects the exposure conditions by analyzing the Focus-Exposure Matrix (FEM), and the classification module is utilized to minimize redundancy in global exposure conditions. The effectiveness of the composite algorithm has been verified by applying it to two representative photolithography processes in the fabrication of HEMT devices. From the experiments, the performance of wafer-level CD has been improved, reducing the uniformity from over 10 % to 2 %, while the CPK has increased from 0.2 to over 2.

A lean approach to robotic process automation in banking

Automation is a concept that has been previously introduced in organizations as a means to improve their processes. However, Robotic Process Automation (RPA) is an emerging method to automate processes with software, which the industry calls robots. These robots perform repetitive and low-complexity tasks previously performed by humans in front of a computer which as is known is the most commonly used feature in a company nowadays. Using the Design Science Research methodology to build up this article, it is argued that RPA is being used idly compared to its full potential which would entail using process improvement techniques before applying the automation itself. Thus, this article proposes a new approach to RPA through the use of Lean techniques. This article assesses two market leaders in RPA. It suggests a framework of activities for organizations that are investing in RPA and that want to take advantage of the capabilities currently offered by this technology. The majority of the demonstration proposal was carried out in a Portuguese private bank in three processes. Depending on the different cases, it had an overall positive evaluation in the field or simulations. Comparing RPA and Lean RPA projects in the number of resources (time, FTE) needed to carry out business processes, the latter approach presented values that were significantly lower and, consequently, satisfactory.

Deploying Bots in Healthcare to Find Revenue Cycle Improvements.

Doing more with less has been a business mantra for decades. Healthcare leaders have implemented flex scheduling and job sharing, streamlined workflows, committed to process improvement techniques such as Lean, hired retirees, gained efficiencies from remote work ... and the list goes on. Each tactic has yielded productivity improvements, yet the need to do more with less continues. Postpandemic challenges include staff recruitment and retention, labor inflation, and dwindling margins, all of which must be addressed while maintaining corporate cultures. The journey with bots described here started in this dynamic environment, and the work has not been single-threaded. The organization featured here-an integrated delivery network-has digital front-door and back-end robotic process automation (RPA) projects underway. The digital front-door initiative supports patient self-registration and automates authorizations and insurance verification processes. The back-end patient financial services RPA project replaces and enhances existing technology. Revenue cycle as a multidepartment function is leadership's poster child for RPA, and the revenue cycle team is tasked to demonstrate the value of the technology. This article covers the initial steps and lessons learned in the process.

Microstructure and mechanical properties of GMAW cladded AA 6063 using friction stir processing as a post-processing technique

ABSTRACT Aluminum alloy being a significant material for many industries, and due to its favourable properties like low density and the high strength-to-weight ratio, is used for cladding. But because of low wear resistance, non-uniform grain structure, and other certain insufficiencies, Friction stir processing (FSP) was applied over the cladded part to overcome these deficits and drawbacks and improve the mechanical characteristics of the produced component further. In this work, mechanical and microstructural characteristics were investigated and analysed by varying rotational speed and number of passes at the time FSP. After FSP finer grains were found, and other solidification defects were eliminated from the final components. Processed part shows the increment in tensile strength, the hardness of the component increases while erosive wear decreases with the number of passes. Maximum hardness and minimum erosion wear rate for all three passes were attained at 598 RPM. Tensile strength and percentage elongation have been found to be highest at three passes at 938 RPM. Microstructure also reflects the finer grains at the highest RPM at the third pass. Also, modern quality management tools and process improvement technique like ANOVA was utilised to formulate the mathematical model and to study the relationship between the input and output of the process.

Integrating Human Resource Management into Lean: Its Implementation and Benefits

Lean management or lean thinking is a process improvement technique that along with Six Sigma is used in an increasing range of workplaces. This special issue focuses on the use of Lean in developed countries. This increased usage reflects a growing propensity for managers to launch initiatives to upgrade the efficiency and productivity of the enterprises that they manage, usually in an attempt to enhance the cost-effectiveness of operations. HR departments are under increasing pressure to ensure business success through effective HR practices. Lean HR can help organizations improve processes, leading to increased productivity and better performance. A major challenge for all organizations is to improve efficiency and to ensure continuous improvement. For the HR department this is a double challenge as the HR department itself should meet the requirements of the organizations it serves in an efficient way, and the HR department should be an active partner in promoting and training improvement actions in relation to the main tasks of the organization. Lean implies a bottom-up approach; it requires empowerment and involvement of all employees and a new type of leadership. This paper will discuss some experiences gained so far and present some potentials of this approach. One concrete result has for instance been the redesign of management of course planning in order to ensure better response to new needs, more efficient use of training resources and more robust management of courses

Improving the Efficiency of the Bowden Cable Terminal Injection Process for the Automotive Industry

Control cables transfer force between two separate locations by a flexible mean, and hence, they are important in the automotive industry and many others; their terminals interact with both moving and moved mechanisms, so they must be strong. Cable terminals are commonly made of ZAMAK and are created by injection molding. However, such a production method requires leaving extra material to allow the correct molding, also known as sprues, which are removed later in the process. In this case, the sprues were separating from the terminals in an uncontrolled way. In this work, the cause of sprues separating prematurely from the terminals in a production line is addressed. The whole process was analyzed, and each possible solution was evaluated using process improvement techniques and the Finite Element Method, leading to the best solutions. Molds, mold structures, and auxiliary equipment were improved, resulting in a minimally invasive intervention and remaining compatible with other equipment. Cost analyses were done, indicating an investment return in less than a year. The modification led to a reduction of 62.6% in the sprue mass, while porosity was reduced by 10.2% and 55.9%, corresponding to two terminal models. In conclusion, the interventions fulfilled the requirements and improved the operation of the line.

A Process Improvement Technique for Silicon Manganese Alloy in A Smelter

A Process Improvement Technique for Silicon Manganese Alloy in A Smelter

Mineralogical Properties of a Refractory Tantalum-Niobium Slag and the Effect of Roasting on the Leaching of Uranium-Thorium.

In order to realize sustainable development, it is beneficial to explore an appropriate process to recover the radionuclides contained in tantalum-niobium slag. By micro-mineralogical analysis and roasting experiments, the effect of uranium-thorium leaching from a refractory tantalum-niobium slag is investigated. The uranium and thorium content in the slag is 2.26 × 103 mg/kg and 7.84 × 103 mg/kg, which have large recovery value. As the surface area and pore size of the slag are very small, the leaching agent cannot fully penetrate the particles. Various methods of characterization are used to analyze the mineralogical properties of roasted slag at different temperatures. The leaching ratio of U-Th is 90.84% and 96.62% at the optimum roasting temperature of 500 °C, which are about 39% and 27% higher than original samples. The oxidants Fe3+, O2 and Mn can also promote the conversion of insoluble U(IV) to soluble U(VI). Roasting reduces the content of organic C and S, thereby preventing reduction of U(VI), and increasing pore size as well as specific surface area also promote radionuclide leaching. Thus, the roasting method at 500 °C can destroy the surface wrapping structure of radionuclides, reduce the internal density of minerals, and improve uranium-thorium leaching ratio significantly. It is of great practical significance to reduce the radioactive hazard of waste tantalum-niobium slag and to strengthen the sustainable utilization of resources by suitable process improvement techniques.

A Nature-Inspired Metaheuristic Optimization Algorithm Based on Crocodiles Hunting Search (CHS)

The increasing difficulty of actual-world optimization problems has prompted computer researchers to regularly produce additional process improvement techniques. Metaheuristic and evolutionary computing are very popular in nature-inspired optimization methods. This paper introduces the crocodile search algorithm (CHS), which is a revision of a new metaphorical algorithm based on the hunting behavior of crocodile herds. Various adaptive and arbitrary variables are combined within this algorithm to indicate the exploitation and investigation of the exploration area in various discoveries of optimization. The performance of the CHS is measured in different test phases. Initially, a collection of famous experiment events including unimodal, multi-modal, and composite functions are applied to examine exploitation, exploration, local optima avoidance, and convergence of CHS. The CHS algorithm achieves a regular frame for the airfoil with a pretty low drag, which explains that the methods can be efficient while working physical difficulties including restrained plus unknown search.

Process intensification and control strategies in cooling crystallization: Crystal size and morphology optimization of α-PABA

This study explores the process intensification techniques and process control strategies on the product properties optimization. α-PABA, a long needle-like shape, can cause problems for the downstream processing. This study proposes ultrasound technique, supercooling control (SSC), and temperature cycling (TC) technologies to optimize the morphology and crystal size distribution of α-PABA. Firstly, the solubility and metastable zone of α-PABA in ethanol solvent are measured to determine the operational range. Next, the concentration calibration model is established to correlate the solubility with the ATR-FTIR intensity and temperature qualitatively. Furthermore, the process improvement techniques and control strategies are introduced to optimize the products. The ultrasound intensification contributes to produce the uniform crystal seeds. The SSC is benefit for the crystal growth, and can reduce the L/D ratio of the crystal product. While, TC is an efficient tool to eliminate the fine crystals. Moreover, the combination of ultrasound, SSC, and TC technology can show a significant improvement on the product particle aspects. The L/D ratio, crystal size, crystal morphology can show different degree of improvement under the combination techniques. At last, the outlook and perspectives on the process analytical technology are developed.

Get with The Guidelines and Guideline Directed Medical Therapy: Why it Matters

Despite therapeutic advances, the epidemic of heart failure (HF) is as challenging as ever. Gaps in prescribing, dose intensification, and adherence leave the vast majority of patients on suboptimal treatment regimens. Without a serious commitment to improving processes of care, many of the scientific advances now available to patients with HF are lost. The tools of process improvement bring operational processes and medical evidence together through guidelines, data standards, quality metrics and performance measures, national registries and benchmarking. Participation in national clinical registries/quality improvement programs offers a method for accurately assessing processes and outcomes and offers feedback on how individual hospital and clinician practices compare with their peers through benchmarking performance against aggregate national or similar hospital outcomes following adjustment for case mix. These quality improvement programs also help share and disseminate best practices and process improvement techniques that can be tailored and implemented locally. A notable example of a national clinical registries/quality improvement program in HF is the American Heart Association's Get With The Guidelines. GWTG-HF is an in-hospital program for improving care by promoting consistent adherence to the latest scientific treatment guidelines. Hospitals participating in GWTG-HF have been able to achieve and sustain high rates of use of the full set of guideline-directed medical therapies, along with provision of HF patient education. Quality of care and clinical outcomes for participating hospitals have been shown to be superior to that of comparable hospitals not participating. It is estimated that if process improvement for HF treatment were implemented optimally more than 100,000 lives a year of HF patients in US each could be saved. Despite therapeutic advances, the epidemic of heart failure (HF) is as challenging as ever. Gaps in prescribing, dose intensification, and adherence leave the vast majority of patients on suboptimal treatment regimens. Without a serious commitment to improving processes of care, many of the scientific advances now available to patients with HF are lost. The tools of process improvement bring operational processes and medical evidence together through guidelines, data standards, quality metrics and performance measures, national registries and benchmarking. Participation in national clinical registries/quality improvement programs offers a method for accurately assessing processes and outcomes and offers feedback on how individual hospital and clinician practices compare with their peers through benchmarking performance against aggregate national or similar hospital outcomes following adjustment for case mix. These quality improvement programs also help share and disseminate best practices and process improvement techniques that can be tailored and implemented locally. A notable example of a national clinical registries/quality improvement program in HF is the American Heart Association's Get With The Guidelines. GWTG-HF is an in-hospital program for improving care by promoting consistent adherence to the latest scientific treatment guidelines. Hospitals participating in GWTG-HF have been able to achieve and sustain high rates of use of the full set of guideline-directed medical therapies, along with provision of HF patient education. Quality of care and clinical outcomes for participating hospitals have been shown to be superior to that of comparable hospitals not participating. It is estimated that if process improvement for HF treatment were implemented optimally more than 100,000 lives a year of HF patients in US each could be saved.

Barriers to implementing digitalization in the Indian construction industry

PurposeThis research paper aims to analyze the critical barriers to implementing digitalization in the Indian construction industry as Indian construction companies are lagging in the implementation of digital technologies in the work environment.Design/methodology/approachIn this research paper, a qualitative research approach is adopted, and multiple detailed interviews are conducted with industry and academic experts. Further, multi-criteria decision-making (MCDM) techniques are used to finalize the prioritization among various alternatives. The fuzzy-decision-making trial and evaluation laboratory (Fuzzy-DEMATEL) and interpretive structural modeling (ISM) techniques are employed to find the exact relationship among the identified alternatives.FindingsThis study identifies 14 critical barriers from an extensive literature review and multiple interviews with industry professionals, and further driving and critical barriers are identified.Research limitations/implicationsIn this research paper, an exploratory study with a limited number of respondents from a large Indian construction company is carried out. Further, a detailed longitudinal analysis can be done to assess the subjectivity of the participants with more advanced statistical tools. However, this research discusses several points pertaining to the implementation of digitalization in the construction industry. The research further identifies the critical barriers to digitalization in the Indian construction industry.Practical implicationsThe finding of the study has two-pronged implications. First, it provides a road-map to the construction industry by highlighting the engagement of top management as the key focus area for successful digitalization. Second, the finding also shows similarity of the digitalization process to the adoption of process improvement techniques like lean and total quality management (TQM), wherein the top management plays a crucial role in ushering in the implementation of a disruptive change.Originality/valueThe research is unique in two ways. First, this is one of the very few attempts to understand digitalization in the Indian context. Second, the research also demonstrates that the combination of fuzzy DEMATEL and ISM techniques can be successfully employed in the emerging field of construction digitalization research.

Quantitative Measurable Concepts to Visualize Business Process Improvement

Business process improvement evaluation enables performance indicators to be used alongside process improvement techniques in order to quantitatively compare measurement information between the as-is and to-be processes. Limitations of the present methods of business process improvement indicate there is scope for looking at the problem in a different way. Business processes are commonly modelled as diagrams which at their fundamental level are complex networks. This suggests the question as to whether complex network analysis (CNA) has anything to contribute to business process improvement. We develop a technique of projecting a business process model onto the sub-space of a complex network and identify the measurable concepts that can be useful in business process improvement. The measurable concepts from CNA are combined with Time and Cost metrics from the simulation technique to visualize and track improvement efforts and satisfy improvement requirements.

Reducing Energy Losses of Steam Boilers Caused by Blowdown with Using the FMEA Method

ABSTRACT In this study, the boiler blowdown was systematically examined and, the risks that increase the energy loss was determined using the potential Failure Mode and Effects Analysis (FMEA) method. Risk priority numbers (RPN) were calculated for each potential risk. It was revealed that ‘Performing more blowdown than it is necessary’ has the highest priority score. Improvement opportunities were identified by using the tree diagram, which is one of the process improvement techniques. Three suggestions were developed, such as flash steam heat recovery, reduction of water conductivity using the reverse osmosis technique, and the use of both methods. Repayment periods were calculated for each investment. If the flash steam unit and reverse osmosis system are applied together, 113.5 KW/h energy can be saved. It has been demonstrated that the FMEA technique can be used in the investigation and reduction of energy loss.

A Scientific Approach of using the DMAIC Methodology to Investigate the Effect of Cutting Tool Life on Product Quality and Process Economics: A Case Study of a Saudi Manufacturing Plant

One of the major priorities for manufacturing companies in the globalized economy is the ability to offer high-quality products to customers at the lowest production cost. Globally, process improvement methods and techniques are used to reduce waste and improve product and service quality. This paper aims to propose a systematic model based on process improvement methodologies and tools to help the manufacturing companies decide on cutting tool life and other manufacturing issues. This research seeks to prove that some common industry practices, such as changing cutting tools in machining processes, can significantly affect the economics of production and the overall performance of the plant. The research is mainly based on analyzing real field data using the DMAIC methodology to identify improvements in order to achieve a balance between economy and quality in a Saudi manufacturing plant. Although the study was concerned only with changing cutting tools in the machining process in an air conditioning plant, its findings and conclusions can be generalized to all manufacturing processes.

Deployment of Lean Six Sigma and KAIZEN Techniques: A Case Study of the Concrete Production Plant for the 750 MW (5 * 150 MW) Kafue Gorge Lower Hydro Power Project

With the fourth industrial revolution on the verge of disruption, businesses and production companies around the world are trying to emulate the success of Toyota’s remarkable production system with a view of reducing waste and improving quality. Lean production has been the secret for Toyota to be as the most profitable automaker in the world. This paper presents a survey and reviews on how process improvement techniques such as the Lean Six Sigma (LSS) and KAIZEN may be implemented to realize reduced lead time in production processes and to attain the desired quality in concrete. The case study is based on the concrete production plant for the 750 MW (5 * 150 MW) Kafue Gorge Lower Hydro Power Project, which may be considered to have been one of the largest concrete batching plant with a total production capacity of 32 cubic meters. The analysis of the effectiveness and impact of the operation and management methods, i.e., LSS and KAIZEN techniques, were carried out over a period of approximately two years. Through literature review, evaluation of these philosophies was done by first defining waste in materials, time and work force at the concrete production plant. The KAIZEN, which is management techniques focusing on employees’ involvement to ensure continuous improvement and a high success rate of lean implementation at the plant, was applied and used thus creating a feedback kind of plant management technique review mechanism overtime. The complete implementation of the lean production system involves considerable organizational change while maintaining the true north. Furthermore, not only can these methods be used to realize Industrial Value Chain through lead time reduction and quality optimization of concrete but also provides applied management and economical improvements with assured reduced Takt-Time realization at the production plant.

Lean Six Sigma project selection using Best Worst Method

Manufacturing organizations are adopting Lean Six Sigma (LSS) and similar process improvement techniques in order to enhance their operational abilities. Irrespective of application of these process improvement programs, organizations are encountering major losses due to poor project selection. This study is carried out to determine the actual project selection process at industry level. Project selection is basically a “Multi-Criteria Decision Making (MCDM)” problem and it involves several factors. During the course of study different LSS project selection factors are identified and compared to select the most suitable project. In this study, leading nine project selection criteria have been shortlisted through literature review and expert opinion. “Best Worst Method (BWM)” is used for weight calculation of the selected criteria for project selection in one of the manufacturing organizations in India. BWM takes fewer steps for weight calculation as compared to various MCDM methodologies. Weight along with Pairwise comparison of projects was utilized to prioritize five different projects which are taken into consideration in this study.