The document discusses how the City of Salina, Kansas has applied Continuous Process Improvement (CPI) principles from Lean Six Sigma within the Public Works Department. It notes that since 2012, over 400 improvements have been implemented, saving over 20,000 staff hours (equivalent to 11.5 employees) and $2.9 million. Key strategies for CPI in cities include engaging all staff, applying lean principles, using small expert teams on high impact projects, and standardizing efficient processes.
5. Comparison of the total hours spent on
CPI Activities to the total hours saved
-
5,000
10,000
15,000
20,000
25,000
2012 2013 2014 2015
Increased Capacity CPI Activities
This equals a cumulative ratio
of 2.44 hours saved for
every hour spent on CPI
Activities
8. Key Strategies
for CPI in Cities
3-Engage everyone in eliminating waste
4-Engage management in applying lean
principles
5-Use small
teams of
experts to
work on high
impact
projects
1-Standardize
efficient
processes
2-Identify
workload
requirements
L
e
a
n
CONTINUOUS
PROCESS
IMPROVEMENT
FOR CITIES
SALINA, KANSAS MODEL
9.
10.
11. 82 Improvements (thru June 2015)
1,079 Hours of Increased Capacity
$99,639 Ongoing Reduction in Costs
$747,819 One-Time Cost Reduction
$339,281 One-Time Cost Avoidance
Plus $640,000 more cost reductions
between 2016-2018
Total Benefit = $1,826,739
12. Criteria:
< $1,200 in annual
savings
< 104 hours of
increased capacity
within supervisor’s authority
does not conflict with current policy
Methodology:
Describe waste removed, customer
service improved or problem solved
Indicate equipment costs/other
expenses, $ amount of savings
(money), hours of increased capacity
(time), other benefits
13. Criteria:
Used for problem solving
>$1,200/yr.
> 104 hrs
Requires dept. head
approval
Methodology:
Describe current situation
Identify the root cause
Select solutions
Implement an action plan
Follow-up to ensure success
14. Criteria:
Review a single
process, single
position, or an
entire unit (division
or department)
Methodology:
Define: creates objective
Measure: collect/display data
Analyze: discussion points
Improve: ID all improvements
Control: “Plan, Do, Check, Act”
15. Waiting
Mistakes
Excess Movement or Motion
Do it Right the First Time
Inefficient Processes
Always Do the Right Thing
Transporting Work
Excess Inventory
16. Occurs anytime these
sit idle:
people
paperwork
information
supplies
equipment
It is symptomatic that something
isn’t right; delays or queue time
built into the process.
17. HHW (Quick Fix):
Added a caller ID
system to the facility
phone line
Allows staff to
retrieve telephone
numbers versus missing calls
Staff can contact citizens who leave
messages without leaving a phone #
Results:
Other benefit: Improved
communications and customer
relations; reduced waiting time
18. Mistakes typically occur
due to:
human error
ineffective methods
defective materials
defective equipment
environmental conditions
These can occur any time, any where;
create need for re-work or additional
inspections.
19. EN (Quick Fix):
Clarified criteria that
help staff identify
sidewalk code
violations
Added guidelines to
make sidewalk
violations easier to spot such as
presence of brick, missing sidewalk,
vegetative growth and problems with
driveway approaches
Results:
Other benefit: Reduced staff errors;
improved appearance of community;
reduced potential slips, trips and falls.
20. Needless motion or
movement to
pick up:
supplies/materials
tools/equipment
others
Typically Caused by:
poor worksite design
poor method or process
Elimination improves efficiency; reduces
errors, delays and costs; improves safety.
21. CG (Quick Fix):
Purchased mobile
service carts
for mechanics
Reduces the # of
trips to and from the
mechanics’ main tool box, parts room,
metalwork area, fluid and filter storage
locations, etc.
Results:
Increased capacity: 89 hrs/yr.
22. LF (Process Review):
6S Project: Sort, Set
in order, Shine,
Safety, Standardize
and Sustain
Created specific
locations for tools,
equipment and supplies
Results:
Increased capacity: 88.4 hrs/yr.
Other benefit: Reduced friction among
workers; reduced reaction time for
pumps & hoses; improved customer
experience; reduced time separating
trash in roll-off container
23. Build quality into processes
w/right:
equipment
people
place
time
preparation
Error-proof each step to:
remove potential mistakes
provide service faster
ID best practices & standardize them for
everyone’s use.
24. LF (A3 Report):
Rebuilt 20-year old old
truck scale in lieu of
replacement
Installed prefab deck and
replaced structural &
mechanical parts as needed
Results:
$ Saved: $42,590 (cost avoidance)
Other benefit: Reduced inconvenience
to landfill customers (less time to
repair than replace)
25. TC (A3 Report):
Repurposed an old
trailer as a recycling
container for
aluminum
Increased revenue
into the general fund - aluminum is
more valuable than mixed metals,
which are sold as “scrap iron”
Results:
$ Increased Revenue: $800
26. Occur when entire process
or step is:
unnecessary
lacking value
shouldn’t be
done
able to be
done better
It is anything that results in:
duplication of effort
friction or chronic annoyance
Includes work a customer wouldn’t pay
for if they knew about it.
27. LF (Process Review):
Right-size cells
Survey internally
Pre-excavate cells
New leachate pond
Gravity line vs.
force mains
Electrical vs. pneumatic pumps
Reduce sand for leachate conveyance
CAT-certified rebuild vs. new
Open 1 hour later on Saturdays
Balance workload of LF staff
Reduce tire punctures
Adjust tipping fees
Results:
$ Saved: $1,077,114
28. Streets (A3 Report):
Improved City Code
for turf, grass,
vegetation and
weed ordinance
Reduced total acreage
of the right-of- way
mowing contract
and placed more equitable
responsibilities on property owners to
maintain the ROW.
Results:
$ Saved: $70,500/3-yr. contract
Other benefit: Improved community
standards, developed FAQ, sent
individualized letters to about 800
affected citizens
29. Streets (Quick Fix):
Avoided costs by
converting a 1999
dump truck with a
chassis-mounted salt
spreader into a flat-bed
truck by using
salvaged bridge planks enabling it to
be used as a salt- spreader, water truck
or a flat-bed utility truck.
Results:
Other benefit: Extends its useful life
and expands its capabilities
30. Streets (A3 Report):
Repaired & modified a
2003 Sanitation
packer truck into a leaf
collection truck
Avoided the need to
purchase a used truck or new leaf
system
Results:
$ Saved: $46,333.40 (cost avoidance)
Other benefit: Extends its useful life
and expands capacity over previous
truck, packer unit can be reinstalled
31. Always do/enforce what is
correct:
morally
ethically
legally
safely
This includes always being:
professional & courteous
considerate & helpful
“The way you treat a customer, when you
don’t owe them anything, is the ultimate
test of character.”
32. Streets (A3 Report):
Built a post driver
that attaches to
front of a wheel
loader to set posts
during special events
Employee no longer
must hold pole while its being driven
Reduces the number of bent poles
Enables faster installation
Results:
Increased capacity: 8 hrs/year
Other benefit: Reduced employee
safety risks considerably
33. DPW (A3 Report):
Created directional
traffic flow within
Public Works
grounds to
improve line-of -
sight when
employees exit
Reduced the likelihood of accidents
for employees and the public
Preserved 4 much-needed employee
parking spaces
Results:
Other benefit: Reduced likelihood of
employee/public accidents
34. No (little) value in transporting:
materials
products
information
services
Each time, there is risk of:
loss or damage
inadvertent change
In many service processes, paperwork
loops back multiple times & it waits in a
queue.
35. DPW/EN (Quick Fix):
Added scan
capability to office
copier/printer
DPW: Eliminated
need to drive to
another building for scanning
EN: Scans/emails excavation permits
in lieu of printing/distributing them
Results:
$ Saved: $6/year
Increased capacity: 4 hrs/year
Other benefit: Increased productivity
36. CG (Process Review):
CG: Eliminated need
to print/distribute
monthly reports for
fuel/parts/labor
reports to depts.
CG: Created
electronic reports, developed dept.
files, imports files & notifies depts.
automatically
EN: scans/emails excavation permits in
lieu of printing/distributing them
Results:
$ Saved: $74.22/year
Increased capacity: 49.2 hrs/year
Other benefit: Faster response
37. Anytime materials, work,
goods aren’t:
immediately
consumed
worked on
shipped to
final customer
Typically results from:
overproduction
over-purchasing
Negotiate for just-in-time shipping vs.
ordering bulk quantities that require
storage over time.
38. CG/Admin/EN:
CG: Reduce quantities
of on-hand parts and
implement a just-in
-time inventory
system
Admin/EN: Implement retention and
electronic imaging policy (scan/save
documents to Laserfiche) to improve
records management
Results:
To Be Determined
42. 10%
20%
40%
30%
Hike & Bike Trail Composition
Course Road Sand
1/4" Stone Chips
CS-2 Existing
Material
AB-1 Aggregate
Base
Standardize
mix design &
eliminate cost
of hiring
contractor for
hike/bike
trail by using
City staff.
43. Hike & Bike Trail Composition
Reduce the amount of staff time
spent collecting litter by 50 percent
annually.
Potential Increased Capacity:
750 - 875 hours
44.
45. Bryon Johnson
Director of Process Improvement
bryon.johnson@salina.org
785-309-5790
Jim Teutsch
Public Works
Operations Manager
jim.teutsch@salina.org
785-309-5750
Notas del editor
We began our efforts in 2012. CPI in government takes time. It is critical to think of this not as a separate entity existing alongside the other things we do in public works or any government function for that matter, but an integral part of the operation, a shift in thinking; truly a culture change.
Early on it became apparent that you have to have an aggressive communications campaign: as part of weekly meetings, in conversation with employees, part of employee performance evaluations, in visual displays and information boards.
There is a fair amount of skepticism. While changing people’s minds can be a difficult process, it can be done, but you have to find champions to the cause, train them and public acknowledge their efforts. Celebrate small successes and find ways to highlight positive change.
Have consistent messaging.
Explain the plan (Lean Six Sigma) and the reasons for doing it (CMO’s burning platform – insufficient revenues to offset costs.)
Explain the long-term goals. (Identifying and eliminating waste to save time or money)
Discuss milestones (hours or dollars saved) on a regular basis.
Share successes of others (they are often transferable from one department to another.)
It can have dramatic results when applied in this manner as you can see. Thus far, we’ve saved nearly $1.8 million and that amount grows each year.
When you saved enough capacity (1,780 hours for a FTE), you have the potential into converting that capacity into dollars saved. We’ve thus far been able to opt not to fill open positions that occur through attrition.
Increased capacity: annual time savings
Ongoing reductions in cost: these occur perpetually as a result of changed processes
One-time cost reductions: the reduction in expenses of single purchase items
One-time cost avoidance: avoiding the need to purchase goods or services
Criteria for a CPI Quick Fix
less than $1200 in annual savings (less than $100 per month)
less than 104 hours of increased capacity annually (less than 2 hours per week)
within the supervisor’s approval authority
(NOTE: any operational change that would require the approval of the Department Head is to be submitted using an A3 Report)
does not conflict with current policy
Identify Waste & Improve Customer Service (W-MEDIATE)
Waiting for people, paperwork, information, supplies, or equipment
Mistakes/defects that require repair, rework, inspection, or verification
Excess movement or motion of workers or equipment
Do it right the first time – build quality into your process
Inefficient processes including non-value added work, work that the customer would not be willing to pay for if they knew about it, duplication, or friction
Always do the right thing
Transporting of work
Excess inventory
Briefly describe what you did to eliminate waste, improve customer service, or solve a problem and submit this form to your supervisor for approval. Once approved implement immediately, then send a copy to both your Director and the Process Improvement Director.
Equipment purchase costs or other expense:
$ Saved: 0
Hours of Increased Capacity:
Other Benefit:.
EXPLAIN WHAT YOU DID: .
Use this report when solving a problem or concern ($1200 or more in value, 104 or more hours of increased capacity)
Include current and proposed process documentation forms, or before and after photos, or other before and after descriptions as appropriate)
Approval authority is delegated to each Director for all recommendations that result in $15,000 or less in annual savings, or 250 hours or less of annual increased capacity.
Use this report review and update processes
We’ll discuss the definitions for each of these and provide one or more examples of projects we’ve done to help illustrate each principle.
Waiting – occurs any time people, materials, or service requests sit idle. It is symptomatic that something is not right. This includes delays or queue time that is built into a process. Any time work stops and sits, the process is inefficient. Any time there is WIP (work-in-progress), the process is inefficient. The traditional methods of batch and queue are contrary to lean methodology and are to be eliminated.
Waiting – occurs any time people, materials, or service requests sit idle. It is symptomatic that something is not right. This includes delays or queue time that is built into a process. Any time work stops and sits, the process is inefficient. Any time there is WIP (work-in-progress), the process is inefficient. The traditional methods of batch and queue are contrary to lean methodology and are to be eliminated.
DPW Project: Improved communication and reduced waiting time by adding call waiting and caller ID to the HHW phone line. If another call is received, the phone displays the caller’s telephone number. It also enables staff to contact citizens who leave messages without leaving their phone number.
Mistakes/Defects – occur due to human error, ineffective methods, defective materials, defective equipment, or environmental conditions. They can occur anytime and anywhere, but are always symptomatic of waste. Mistakes/defects create repairs, rework, inspections, and verifications. These should always be minimized and completely eliminated where possible.
Mistakes/Defects – occur due to human error, ineffective methods, defective materials, defective equipment, or environmental conditions. They can occur anytime and anywhere, but are always symptomatic of waste. Mistakes/defects create repairs, rework, inspections, and verifications. These should always be minimized and completely eliminated where possible.
Mistakes
Reduced errors when enforcing safety codes pertaining to sidewalk violations. This was done by clarifying criteria that identify sidewalk code violations and adding guidelines that will make it easier to spot them.
Excess Movement of Workers – is the needless movement of people to pick up or move materials or equipment. As a general rule, excess movement or motion is waste, unless specifically prescribed to maintain a healthy body. The elimination of excess movement or motion improves efficiency, reduces errors and delays, reduces costs, and improves safety.
Excess Movement of Workers – is the needless movement of people to pick up or move materials or equipment. As a general rule, excess movement or motion is waste, unless specifically prescribed to maintain a healthy body. The elimination of excess movement or motion improves efficiency, reduces errors and delays, reduces costs, and improves safety.
Excess Movement or Motion of Workers – Increased capacity by purchasing a service cart that reduces the number of trips to and from the mechanic’s main tool box.
Excess Movement of Workers – is the needless movement of people to pick up or move materials or equipment. As a general rule, excess movement or motion is waste, unless specifically prescribed to maintain a healthy body. The elimination of excess movement or motion improves efficiency, reduces errors and delays, reduces costs, and improves safety.
Excess Movement or Motion of Workers – Increased capacity by performing a 6S project at the Landfill where they created specific locations for tools, equipment, and supplies in each of their storage buildings so that they could be readily found.
Do it Right the First Time – Build Quality into Your Process – requires the right equipment, and the right people, at the right place, at the right time; to prepare up front before starting a task, to error proof each step in a process - removing even the potential for mistakes; to provide the service expected on time or faster; to identify the very best way of doing something and then standardize it for everyone’s use.
Do it Right the First Time – Build Quality into Your Process – requires the right equipment, and the right people, at the right place, at the right time; to prepare up front before starting a task, to error proof each step in a process - removing even the potential for mistakes; to provide the service expected on time or faster; to identify the very best way of doing something and then standardize it for everyone’s use.
Facilitated faster response times at the onset of floods or other disasters by reconditioning an unused trailer, building supports to hold barricades, and pre-loading barricades inside the trailer.
Do it Right the First Time – Build Quality into Your Process – requires the right equipment, and the right people, at the right place, at the right time; to prepare up front before starting a task, to error proof each step in a process - removing even the potential for mistakes; to provide the service expected on time or faster; to identify the very best way of doing something and then standardize it for everyone’s use.
Increased revenues by separating aluminum from other scrap metal and selling it separately from other items.
Inefficient Processes - occurs when the entire process or a step in the process is unnecessary, adds no value to the desired result, should not be done at all, or can be done more efficiently another way. It includes work that the customer would not be willing to pay for if they knew about it. And it is anything that results in a duplication of effort, or creates friction, which is a chronic annoyance that is thought to be too trivial to bother the boss with.
“Customer Ergonomics”
Inefficient Processes - occurs when the entire process or a step in the process is unnecessary, adds no value to the desired result, should not be done at all, or can be done more efficiently another way. It includes work that the customer would not be willing to pay for if they knew about it. And it is anything that results in a duplication of effort, or creates friction, which is a chronic annoyance that is thought to be too trivial to bother the boss with.
Do it Right the First Time – This began when a valuable customer, responsible for a full 1/5 of the landfill’s total revenue decided to re-open a previously-closed landfill within their City.
Performed a process review of landfill operations and identified ways to reduce costs over the next 5 years by: (1) pre-excavating cells as far as possible, (2) creating a leachate pond and using gravity fed leachate conveyance lines, (3)switching to electrical pumps in lieu of pneumatic pumps when pumps are still required, (4) reducing the amount of sand use for leachate conveyance, (5) having the D7 Dozer and the 826H Compactor undergo a Cat-certified rebuild, rather than replacing them with new equipment – this reduced replacement costs by 56%, (6) reducing hours on Saturday (open 1 hour later), and by (7) balancing the workload of the landfill staff.
Inefficient Processes - occurs when the entire process or a step in the process is unnecessary, adds no value to the desired result, should not be done at all, or can be done more efficiently another way. It includes work that the customer would not be willing to pay for if they knew about it. And it is anything that results in a duplication of effort, or creates friction, which is a chronic annoyance that is thought to be too trivial to bother the boss with.
Do it Right the First Time – Reduced mowing costs by reducing the amount of ROW area mowed by a city contractor by 40%.
Inefficient Processes - occurs when the entire process or a step in the process is unnecessary, adds no value to the desired result, should not be done at all, or can be done more efficiently another way. It includes work that the customer would not be willing to pay for if they knew about it. And it is anything that results in a duplication of effort, or creates friction, which is a chronic annoyance that is thought to be too trivial to bother the boss with.
Inefficient Processes - Converted a 1999 truck with a chassis-mounted salt spreader into a flat-bed truck using salvaged bridge planks. The truck may now be used as a salt spreader, a 550-gallon water truck or a flat-bed utility vehicle.
Inefficient Processes - occurs when the entire process or a step in the process is unnecessary, adds no value to the desired result, should not be done at all, or can be done more efficiently another way. It includes work that the customer would not be willing to pay for if they knew about it. And it is anything that results in a duplication of effort, or creates friction, which is a chronic annoyance that is thought to be too trivial to bother the boss with.
Inefficient Processes - The Streets Work Group used a 1987 modified dump truck for leaf collection, which became dilapidated, unreliable, and inadequate for leaf collection. The work group needed to find a replacement for the old leaf truck. The old leaf storage truck was in very poor condition and no longer safe for use. It regularly broke down, resulting in employees spending unnecessary time repairing the vehicle and frequently lost time while collecting leaves due to breakdowns. The old vehicle was put on auction and sold. We replaced it with a modified Sanitation packer, redesigned back end of packer to accommodate leaf collection hose from the vacuum. This increased capacity by 5 yards due to the size of packer and ejector wall.
Annual dollar savings: COST AVIODANCE
Purchase a used truck or new leaf system: $48,000.00
Transfer of used packer truck $0.00
Auction price of old leaf storage truck -$1,400.00
Cost of modification to old packer truck -$266.60
Total: $46,333.40
Always Do the Right Thing - means to always do what is morally, ethically, and legally correct. Practice safety first. Always be professional, courteous, considerate, and helpful. The way you treat a customer, when you don’t owe them anything, is the ultimate test of character.
Always Do the Right Thing - means to always do what is morally, ethically, and legally correct. Practice safety first. Always be professional, courteous, considerate, and helpful. The way you treat a customer, when you don’t owe them anything, is the ultimate test of character.
Always Do the Right Thing - Increased capacity and reduced safety risks considerably by building a post driver that can be attached to the front of a wheel loader bucket in order to help set T-posts into the ground more safely. Previously an employee had to physically hold the post under the bucket of the wheel loader in order to set it.
Always Do the Right Thing - means to always do what is morally, ethically, and legally correct. Practice safety first. Always be professional, courteous, considerate, and helpful. The way you treat a customer, when you don’t owe them anything, is the ultimate test of character.
Always Do the Right Thing - Created a single directional traffic flow plan in and out of the Public Works Facility in order to eliminate the safety hazard when pulling out of the driveway next to the Building Maintenance building at 418 Ash Street.
Transporting of Work – refers to the movement of work. There is no value in transporting materials, product, information, or services from one location to another; and every time it is transported the risk of damage, loss, or inadvertent change increases. In many service processes, paperwork loops back on each activity several times…and waits in a queue each time.
Transporting of Work – refers to the movement of work. There is no value in transporting materials, product, information, or services from one location to another; and every time it is transported the risk of damage, loss, or inadvertent change increases. In many service processes, paperwork loops back on each activity several times…and waits in a queue each time.
Transporting of Work – Public Works Facility Eliminated the requirement to travel to the City Office building in order to scan documents by asking CT to create an electronic pathway that would activate the scanning feature on equipment already in service.
Transporting of Work – refers to the movement of work. There is no value in transporting materials, product, information, or services from one location to another; and every time it is transported the risk of damage, loss, or inadvertent change increases. In many service processes, paperwork loops back on each activity several times…and waits in a queue each time.
Transporting of Work – Developed a file on the P Drive where the Central Garage Monthly Reports could be stored, thereby providing all departments with direct access to their information, while eliminating printing and distribution costs.
Excess Inventory – occurs anytime raw materials, work-in-progress, or finished goods are not immediately consumed, worked on, or shipped to the final customer. The primary cause, although not the only one, is either overproduction by manufacturing companies or over-purchasing by customers. Traditionally, parts and supplies are purchased in bulk quantities in order to take advantage of manufacturing discounts. These purchases then require storage facilities to house them until used, thereby boosting the actual cost to more than the anticipated savings. Over-purchasing may also result in obsolescence as better products come into the market place, or as equipment is replaced with newer, improved versions.
Transporting of Work – refers to the movement of work. There is no value in transporting materials, product, information, or services from one location to another; and every time it is transported the risk of damage, loss, or inadvertent change increases. In many service processes, paperwork loops back on each activity several times…and waits in a queue each time.
Transporting of Work – Currently working on reducing parts room inventory in CG and eliminating paper files whenever possible.
Welding Screens: Cost $40; Improves employee/customer safety.
Gas Bottle Storage Cage: No cost; Workplace safety/OSHA compliance.
Salvaged: $19,600-$2,907 (buy-back) Received $16,693 in parts.
Flood/Barricade Trailer: Faster response times for floods or other disasters.
Mowing Trailer: Increased capacity by 21.7 hours annually and avoided costs of new trailer: $4,098.90 + $149.95 landscape package - $617.63 cost/materials.
Traffic Loops: Saved 4-hours annually and less inconvenience to motorists.
Stake Puller: $220 annually (stakes recovered); 19 hours annually (time savings)
One-time revenue: $640.50 (scrap metal sales); Increased usable all-weather storage space
Portable Concrete Poles: 30 hours annually for snow/safety fence installation on pavement for special events
Transporting of Work – refers to the movement of work. There is no value in transporting materials, product, information, or services from one location to another; and every time it is transported the risk of damage, loss, or inadvertent change increases. In many service processes, paperwork loops back on each activity several times…and waits in a queue each time.
Transporting of Work – Developed a file on the P Drive where the Central Garage Monthly Reports could be stored, thereby providing all departments with direct access to their information, while eliminating printing and distribution costs.
Transporting of Work – refers to the movement of work. There is no value in transporting materials, product, information, or services from one location to another; and every time it is transported the risk of damage, loss, or inadvertent change increases. In many service processes, paperwork loops back on each activity several times…and waits in a queue each time.
Transporting of Work – Developed a file on the P Drive where the Central Garage Monthly Reports could be stored, thereby providing all departments with direct access to their information, while eliminating printing and distribution costs.
Transporting of Work – refers to the movement of work. There is no value in transporting materials, product, information, or services from one location to another; and every time it is transported the risk of damage, loss, or inadvertent change increases. In many service processes, paperwork loops back on each activity several times…and waits in a queue each time.
Transporting of Work – Developed a file on the P Drive where the Central Garage Monthly Reports could be stored, thereby providing all departments with direct access to their information, while eliminating printing and distribution costs.