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Process Redesign
for Health Care
Using Lean
Thinking
A Guide for Improving Patient Flow and
the Quality and Safety of Care
Process Redesign
for Health Care
Using Lean
Thinking
A Guide for Improving Patient Flow and
the Quality and Safety of Care
David I. Ben-Tovim
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
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vii
viii ◾ Contents
Waste 3: Rework...................................................................................................... 24
Wastes 4 and 5: Transportation and Motion............................................................ 24
Wastes 6 and 7: Overprocessing and Overproduction.............................................. 24
Waste 8: Neglecting Skills and Talents.....................................................................25
Flow..........................................................................................................................25
Principle 4: So That the Customer Can Pull..................................................................25
Principle 5: As You Manage toward Perfection............................................................. 26
5 Health Care Is Not Manufacturing.............................................................................27
Placing an Order: Customers and Raw Materials.............................................................. 27
Deterioration.................................................................................................................... 28
Redesign Double Vision.................................................................................................... 28
Health Care Is Complicated............................................................................................. 29
Adaptive Problems........................................................................................................ 29
6 Knowledge Work.........................................................................................................31
The Nature of Knowledge Work....................................................................................... 32
Supervised but Not Subordinated..................................................................................... 32
Knowledge Workers Own Their Knowledge Capital.........................................................33
Machines Extend Knowledge Work, Not Replace It......................................................... 34
Design and Redesign........................................................................................................ 34
7 Redesigning Care: Authorization, Permission, Teams, and Governance....................37
Authorization.................................................................................................................... 38
Permission........................................................................................................................ 39
The Redesign Team........................................................................................................... 39
Governance....................................................................................................................... 40
8 The Virtuous Circle of Process Redesign and the Health Care A3..............................43
9 Identifying the Problem..............................................................................................47
Primary Purpose, Problems, and Concerns........................................................................47
What Kind of Problem and Where to Start?..................................................................... 48
Evidence........................................................................................................................... 48
Keep It Simple, Be Prepared to Be Surprised.................................................................... 49
10 Defining the Scope......................................................................................................51
The Benefits of Starting with Scope...................................................................................51
Sphere of Influence............................................................................................................53
Scope and Scoping: An Evolving Task...............................................................................55
11 Diagnosis (1): Mapping...............................................................................................57
The Big Picture and the Big Picture Map...........................................................................57
The Process of Big Picture Mapping: A Social Intervention...............................................59
Setting Up and Undertaking a Big Picture Mapping........................................................ 60
Closing the Session........................................................................................................... 62
12 Diagnosis (2): Direct Observation...............................................................................63
External or Internal Redesign Capacity?........................................................................... 63
The Structure of the Learning to See Phase...................................................................... 64
Contents ◾ ix
14 Measurement...............................................................................................................73
Measurement for Redesign—Types of Measurement........................................................ 73
Qualitative and Quantitative Measures........................................................................ 73
Parametric and Nonparametric Measures................................................................ 75
Computers or Paper and Pencil................................................................................ 75
The Basic Triad of Analysis Design....................................................................................76
The Run Chart............................................................................................................. 77
Measurement Focus: Time, Money, and Outcomes.......................................................... 79
Measuring Processes or Outcomes............................................................................... 80
Summary.......................................................................................................................... 80
Introduction: An Accidental
Redesigner
I am an accidental redesigner. Yet, I have spent more than 10 years attempting to redesign the way
care is organized and delivered in hospitals and health services.
I am a psychiatrist and clinical epidemiologist by background. The Flinders Medical Centre
is a 500-bed teaching general hospital in Adelaide, South Australia. In 2000, I became its
Director of Clinical Governance. My job was to oversee safety and quality systems throughout
the hospital.
The main problem was apparent. The Emergency Department had become catastrophically
congested. Patients were being managed in far-from-optimal settings, and problems that started
in the Emergency Department were showing up all over the hospital.
The hospital was not facing an excess patient load, just the work the community had every
right to expect the hospital to be able to manage. A variety of efforts had been made to improve
things. None had provided lasting relief. Then, my colleague Melissa Lewis came across some-
thing called Process Mapping on the Internet. It seemed to involve bringing together the people
who worked in a unit and asking them what they did to move the patients through the unit.
We thought Process Mapping might help us understand what was going on. Although the senior
staff members who worked in the Emergency Department were confident that they had a pretty
good handle on how the department worked, they were willing to try anything to get the depart-
ment working, including Process Mapping.
Process Mapping
One Tuesday morning, about 20 staff from the Emergency Department, Melissa Lewis, and
I gathered in the Emergency Department seminar room. Every discipline group working in the
department was represented, from the Patient Service Assistants who did the cleaning, fetching,
and carrying, to the most senior Emergency Physicians.
Melissa and I decided to ask the participants to describe what they did, step by step, from the
moment a patient arrived at the glass doors at the entrance to the department until that patient left
the department and went home or was admitted to an in-patient unit.
1
2 ◾ Process Redesign for Health Care Using Lean Thinking
Over three long sessions, we mapped out the sequences of care the department provided. It was
a revelation. As soon as we started, it became clear just how confusing the care processes had
become. The Emergency Department staff were as surprised by this as we were.
Every patient who comes to a major Emergency Department in Australia sees a specialized
Triage nurse. The Triage nurse is stationed, literally and metaphorically, at the front door. She or
he makes a very brief clinical assessment of all the patients and allocates a Triage score to each
one. A Triage score is the Triage nurse’s assessment of how urgently the rest of the staff in the
department need to begin the work of providing definitive care: immediately, within 10 minutes,
within 30 minutes, within 60 minutes, or within 2 hours. Many of the problems in the Emergency
Department seemed to begin with the way Triage scores were being used. The Triage scores not
only described patients but were also used to place patients in queues. Whilst this might seem to
make sense, the case study in Chapter 20 makes it clear why this had become a problem.
As we presented our observations to various groups around the hospital, there was widespread
agreement that something needed to be done—but what?
psychologist completed the team. We established both the team (which included Melissa Lewis,
Jane Bassham, Denise Bennett, Margaret Martin part time, and later Jackie Sincock and Lauri
O’Brien) and a governance structure that brought together the senior hospital leaders. We decided
on a name—Redesigning Care—and got started.
Why Redesign?
Why redesign, not design or improve? It is because the hospital already existed, with skillful and
committed people already doing their best. We were not beginning with a clean slate. On the
contrary, we were trying to improve care processes already in place in an institution that did not
have the luxury of closing down until it got things sorted out.
how Redesign actually occurs. To make that possible, the extended case studies are based on the
materials produced at the time.
Health Care involves people at their most vulnerable and private moments. To minimize the
risk of identifying individuals, details that might identify specific participants, or institutional
issues of any sensitivity, have been altered or removed, and if diagrams or figures are presented that
are based on materials produced during Redesign programs, they have been altered and redrawn
so that anonymity is preserved. Facts or figures that might identify individuals or specific services
have also been altered to minimize the risk of inappropriate identifications. However, every effort
has been made to faithfully describe the spirit of the Process Redesign programs and not make
false claims for program outcomes. However, the case studies have been written up in a format
that clearly separates out various phases of the work involved. That was how the work progressed,
and where major deviations in the progression of work occurred, they have been discussed; how-
ever, case studies are by their nature somewhat simplified representations of a messier reality.
Writing up the case histories has only been possible because of the extensive documentation of
the work as it progressed. It is a tribute to the efforts Denise Bennett and the other team members
put into reporting to governance groups at each step on the way. Denise was a particular force for
good in this area, and much of the credit for the consistency of the documentation must go to her
leadership.
Throughout the text, when a personal contribution by a team member has been particularly
clear, I have tried to identify that person’s contribution to the development of theory or practice,
but again, whilst maintaining confidentiality and recognizing the importance of the team as a
whole.
A Decade Later
A decade after this work began, there is a growing community of Health Care redesigners using
Lean Thinking to redesign and improve Health Care processes, both in Australia and the rest of
the world. I am delighted with the role I and my colleagues have been able to play in this develop-
ment, and with the way the Australasian Lean Health Care Network, which the Flinders group
has been part of from the start, has supported that development in Australasia.
Process Redesign for Health Care is for anyone who is trying to improve how their hospital
or health service delivers care. I hope there is something in it both for the novice redesigner and
the more experienced practitioner curious to learn more. Redesign is never easy. It is hard work.
Things never go quite to plan. But it can be done. Process Redesign is a team effort. When faced
with the common experience of not quite knowing what you are doing or what to do next, as the
Flinders team always said, “have confidence in the method, and don’t miss a step.”
CONTEXT AND I
METHOD
Chapter 2
The term Lean Thinking first appeared in the book The Machine that Changed the World (Womack
et al. 1990). The book was a summary of a global research program into car-making around the
world. Lean Thinking was the term the authors used to sum up the distinctive production and
managerial methods they observed at the Toyota Motor Company.
To understand what excited Womack et al., it’s essential to know something about the evolu-
tion of methods for making large, complicated objects, such as boats or cars. It is possible to look
back in history to fourteenth century Venetian shipyard production or even earlier to the produc-
tion of terracotta warriors for the tomb of the first Emperor of Qin who died in 221 BCE, but the
important period to concentrate on is the end of the nineteenth century. That was when what was
commonly described as the British method of manufacturing gave way to the American method,
out of which emerged mass production as we know it today.
This short history (Lazonick 1981; Reinstaller 2007) is not simply included to make it clear
what Toyota was doing that was different. Modern Health Care makes use of every method of
production, from pre-industrial craft work to the most advanced manufacturing techniques.
Understanding the differences between the methods helps explain why they do not always fit eas-
ily together in the day-to-day work of Health Care.
7
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VOLUME I