Department of Toxic Substances Control (DTSC) Inspection Report - - PowerPoint PPT Presentation

Lean 6-Sigma Program

Shawn Cox (Project Greenbelt)

Department of Toxic Substances Control (DTSC)

Adam Palmer (Project Champion) Keith Kihara (Executive Sponsor)

Inspection Report Project

Enforcement and Emergency Response Division (EERD)

We perform inspections and enforcement on the following:  Universal Waste Facilities (E-Waste)  Hazardous Waste Transporters  Generators  Treatment, Storage, and Disposal Facilities Lean 6-Sigma Program

 Problem Statement: From 2014-2016 DTSC completed about 84% of inspections within 65 days, as required by statute.  Objective: Complete and submit 95% of inspection reports within 30 days.  Primary Metric: Days from the first day of the inspection until submission to the operator.  Project Team: Over 100 years of experience. Christie Bautista Abdalin Asinas Bailey Franklin Ellen Pates Lean 6-Sigma Program

Inspection Report Lean Six Sigma

Van-Anh Le Josilynn Spray Leah White Danny Demarco

Baseline Capability Analysis Capability Six Pack Interval Plot FMEA Scatterplot One-Way ANOVA Fishbone Diagram High Level Process Map Mood’s Median Test 2-Sample T Test Regression Analysis

Lean 6-Sigma Program

Analysis Tools

 Most Non Value Added steps are in the review phase Lean 6-Sigma Program

Initial Process Map

insert process map

= Value Added = Non Value Added = Legally Required = Data Collection

 35 day Inspection Report average  49% completed in 30 days Lean 6-Sigma Program

Baseline Capability

insert capability analysis graph

240 200 1 60 1 20 80 40

UB

Process Capability Report for All inspections

Calculations Based on Weibull Distribution Model

Inspection Reports Completed Days to Completion of Inspection Report

 56 day Inspection Report average  21% of Inspection Reports completed in 30 days Lean 6-Sigma Program

Baseline Capability without E-waste

insert capability analysis graph

240 200 1 60 1 20 80 40

30 Day Goal UB

30 Day Goal

Calculations Based on Weibull Distribution Model

Inspection Reports Completed Days to Completion of Inspection Report

 How E-Waste is different  Not all facilities should use a checklist Lean 6-Sigma Program

Difference Between E-waste and Other Facilities

insert graphical or analysis result

Days to Completion of Inspection Report

Timeframe for Class of Violations

Significant Difference

Class 1 Class 2 Minor No Violations

Lean 6-Sigma Program

Lean 6-Sigma Program

Number of Violations Regression Analysis

 No Significant Relationship

Days to Completion of Inspection Report Number of Violations

 Significantly fewer Class 1 violations from E-Waste Lean 6-Sigma Program

Comparing Violations Found

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Total Inspections Total Violations Total Class 1's

Violation Comparison By Percentage

E-waste All Other

Inspection Report Template – No real template Consultation and Research – It is impossible to know all

• f the California Code of Regulations/Health and Safety

Code Sampling – Not prepared to sample during the inspection Cyclical review phases

Lean 6-Sigma Program

Critical X’s (root causes of problems)

 52 Steps initially Lean 6-Sigma Program

New Process Map

 28 Steps after

= Value Added = Non Value Added = Legally Required = Data Collection

 Checklist for transporter inspections  Class 2 Violation threshold for checklist based inspections (currently a Class 1 threshold)  New inspection report template  Sampling kit  Health and Safety Code / California Code of Regulations database  Penalty Determination Team in the instance of Class 1 Violations  Standardized Cover Letter  Eliminate Branch Chief review of Inspection Reports Lean 6-Sigma Program

Improvement Techniques

Monitor days to completion of Inspection Report by violations and facility type Ensure Report quality through audits Supervisors ensure staff have adequate sampling kits Ensure consistent usage of proper templates

Lean 6-Sigma Program

Control Plan

Before and After – New Process Projected

9/26/201 7 8/22/2017 1 2/6/2016 10/24/2016 9/1 3/2016 6/29/201 6 5/26/2016 4/27/2016 3/22/201 6 2/9/2016 1/7/2016 250 200 1 50 1 00 50

INSPECTION DATE Individual Value

_ X=13.8 UCL=51.6 LB=0 Before After

1 1 1 1 1 1 1

I Chart of Time to Completion by Before

Worksheet: Worksheet 1; 7/20/2017; Created by Shawn Cox

 Inspection Report completion time shifts from 35 to 20 days Lean 6-Sigma Program

19.5

Staff Morale Department Image Staff Efficiency Concise presentation of information Customer Satisfaction Compatible with future technology upgrades

Lean 6-Sigma Program

Additional Benefits

A3 Performance Tracker

A3 Performance Tracker 20

Problem Statement: From 2014-2016 DTSC completed about 84% of inspection reports within 65 days, as required by statute. Primary Metric: Days to completion of Inspection Report Goal: Submit 95% of inspection reports within 30 days while maintaining or increasing the quality of inspection reports. Root Causes (Critical X’s):

• Sampling - Not prepared to sample
• Consultation/Research - CCR/HSC
• Inspection Report Template - No Inspection Report Template
• Cyclical Review Processes

Updated Control Chart: Project Title: Inspection Report Lean Six Sigma Agency/Department: Department of Toxic Substances Control Division/District/Office: Headquarters Champion/Process Owner: Adam Palmer Green Belt: Shawn Cox Executive Sponsor: Keith Kihara Date: 7/17/2017 Baseline Average: 35 Days Current Average: 35 Days Current Capability: 84% in 65 Days General Information: Solution Implementation Tracking: item status New Inspection Report Pilot Use Transporter Checklist Proposed CCR/HSC Database Proposed Sampling Kits Proposed Class Two Violation Threshold Proposed Penalty Determination Team Proposed Standard Cover Letter Proposed Eliminate Branch Chief Review Proposed

262 233 204 175 146 117 88 59 30 1 250 200 150 100 50

• 50
• 100

Observation Individual Value

_ X=35.6 UCL=135.8 LCL=-64.5

1 1 1 1 1 1 1

I Chart of Chronological

Worksheet: Worksheet 1; 7/21/2017; Created by Shawn Cox

 Name: Shawn Cox  Phone: (916) 322-7527  Email: shawn.cox@dtsc.ca.gov

Lean 6-Sigma Program

Green Belt Contact Information