2nd Annual

Lean Six Sigma Laboratories

Improving speed, flow, customer needs and variation in laboratory operations with
the logical blend of Lean and Six Sigma methodology

“Good, better, best, never let it rest, till your good is better
Rendezvous Hotel Melbourne and your better, best” David Rees

18th & 19th May 2009

Embracing the synergy of Lean and Six Sigma methodology to raise the bar of your
laboratories performance

Offering practical industry insights and case
study presentations by:
Kerri Gill National Business Improvement Manager
Coca-Cola Amatil
Ivy Leung Operations Excellence Expert & Knowledge Manager
GlaxoSmithKline
Lean Six Sigma Blackbelt and GMS Site Director Award in 2007
Featuring international case study presentation by:
Professor Aw Tar Choon Senior Consultant – Laboratory
Changi General Hospital (Singapore)
Prof Aw Tar Choon featured his hospital as a role model in discussing the important
components that make up an efficient laboratory without the need for total laboratory
automation. Insights will be given with regard to laboratory planning, laboratory structure,
logistics, laboratory workflow, lean laboratory design and manpower.

Eric Wilkes Global Manager Analytical Services

Fosters Group
Workshop: Taking your laboratory operations quality to the next
Glenn Smith Quality Measurement Manager level
BP Refinery Kwinana How industrial laboratories have implemented Lean Six Sigma concepts
to improve effectiveness, efficiency and customer service
Dr Rajiv Jayasena Compliance & Improvement Manager
CSL Biotherapies Tailor-made for the 2 major sectors: Breakout sessions for Heavy Industries and Life
Science & FMCGs
Professor David I. Ben-Tovim Director, Redesigning Care and Facilitated by:
Clinical Epidemiology
Brian K. Nunnally Ph.D. Associate Director, Validation
Flinders Medical Centre
Wyeth Biotech – USA
David Nielsen Director Automated Laboratory John McConnell Director
SA Pathology Wysowl Pty Ltd

Udit Singh General Manager Laboratory Services

AsureQuality
Gary Pett Process Improvement Manager
NCI Plastics
Dr Andrew Katsifis Research Leader Radiopharmaceuticals
Research Institute
Australian Nuclear Science and Technology Organisation
Michael W McLean Managing Director
McLean Management Consultants Pty Ltd
FAICD, FAOQ, CMC, B.Bus., Prod Eng C, Juran Medallist
Attend this premier conference and gain an insight into:
• Applying lean six sigma techniques and practices to reduce process variability in striving
for perfection
• Getting the support from top management to implement lean six sigma, achieving
desired quality in service
• Overcoming barriers of implementing lean six sigma in your laboratory
• Embarking on productivity improvement actions to enhance levels of performance
• Combining automation, process improvement together with lean six sigma to deliver
faster and higher-quality results
• Achieving testing objectives to reduce variation and optimise laboratory efficiency

What delegates have said about Intelligent Lean Laboratories

*Early Bird & Group Discounts
Ask about our savings
Collaborative Partners
Official Online Media Partner
2008 Conference:
“This conference was very timely as many labs are starting on the journey of implementing
lean systems in labs. This has unique set of challenges by getting together and sharing
these experiences we all benefit”.
Analytical Services Manager
Fonterra
“Excellent conference, the opportunity to see how other labs are implementing lean and
discuss with likeminded people was invaluable”.
Continuous Improvement Project Manager
SGS
“One of the best organised and smoothly run conferences I have attended. The speakers
Media Partner were relevant and the timing and running very smooth”.
Laboratory Manager
Murray Goulburn

conferences
Conference Programme Day One

Monday 18th May 2009

0815 Registration and coffee Workshop:

0845 Opening address from the Chair Implementing lean concepts to improve effectiveness, efficiency and
Glenn Smith Quality Measurement Manager customer service
BP Refinery Kwinana
Module One
Case studies: Understanding variation – Some vital concepts
• The Red Beads Experiment - a practical experiment to demonstrate the concept of
0900 Session One – Case Study stability and which illustrates the Pareto Principle
Empowering the lean mindset with integrated analytical systems in • Stability is not obvious, achieving it, however, is straight forward
the healthcare industry • Understanding the difference between stability and instability, as well as the
• Combining solution and process improvement together with lean to deliver faster and implications
higher-quality results
• Deploying suitable systems and technologies to sustain high quality and consistency in Module Two
your healthcare How laboratories are impacted by poor and unstable analytical
• Striking the balance between lean and analytical systems to maximise gains and processes: Case studies from USA pharmaceuticals illustrating the
efficiency usefulness of control charts
Professor David I. Ben-Tovim Director, Redesigning Care and Clinical • Understand why reducing variation in analytical processes is nearly always the first
Epidemiology priority
Flinders Medical Centre • Understand how a lack of stability in the data drives even higher levels of analytical
error
1000 Session Two – Case Study • Case studies will discuss attacking variability to improve customer service
Continuous process improvement in your Lean journey: A case study
on Changi General Hospital Module Three and Four
• Strategic planning and scorecards for laboratories Identifying and understanding the causes to reduce variation with
• Setting clear targets for measurable return DMAIC
• Driving value and quality into the laboratory • The customer wants three things from a laboratory: Precision, timeliness and low cost.
• Promoting staff participation in continuous improvement projects to generate a sense Why not accuracy?
of belongingness to the program • Application of Little's Law to laboratories: How throughput is dependent on variation
Professor Aw Tar Choon Senior Consultant – Laboratory • Practical Experiment (Audience members participate) that demonstrated the links
Changi General Hospital (Singapore) between Cycle Time, Productivity and Work-In-Progress
• Understand how variation impacts quality, productivity, cycle time and customer
1045 Morning refreshments & networking break satisfaction
• How to develop a plan of attack to reduce variation and transform the laboratory
1115 Session Three - Case Study
Achieving testing objectives by optimising laboratory effectivenessand Your workshop leaders:
efficiency Brian K. Nunnally Ph.D. Associate Director, Validation
• Collecting sufficient and representative information and ranking for relevance Wyeth Biotech – USA
• Managing key background information to handle the demand for data analysis Dr Nunnally has authored numerous publications in the field of analytical chemistry and
• Detecting and minimising testing variation with lean and 6 sigma tools has given lectures in a variety of analytical chemistry subjects. He is an assistant editor
of the journal Analytical Letters (Marcel Dekker, Inc.) and a member of the Analytical
Glenn Smith Quality Measurement Manager
Chemistry Division of the American Chemical Society and the Society for Applied
BP Refinery Kwinana
Spectroscopy Dr Nunnally was the Associate Director for GMP Operations in Vaccine
Analytical Development at Wyeth. The group he led was responsible for all Reference
1200 Session Four – Case Study Standards, Stability, GMP Testing, and Validation for the vaccine candidates Wyeth was
Applying Lean Six Sigma techniques and practices to reduce process developing.
variability in striving for perfection John McConnell Director
• Eliminating defects and errors by using six sigma to re-create the process Wysowl Pty Ltd
• Reducing cycle times and error rates to improve quality of products and services John has consulted to a variety of industries in eight countries and has worked
delivered extensively in the pharmaceutical industry in Australia, North America and Europe. Many
• Assuring quality of products after delivery-and before quality control-just in time clients have simultaneously improved quality, reduced deviations and up to doubled
production production. Perhaps John’s greatest strength is his ability to explain issues such as
• Enhancing laboratory performance in a research environment with lean six sigma by statistical methods and systems theory in such a way that people from the shop floor to
eliminating unnecessary testing the boardroom are able to understand and use the concepts. His use of metaphor and
parables is especially useful in creating not only understanding, but also impact. He is a
Dr Andrew Katsifis Research Leader Radiopharmaceuticals Research Institute
gifted speaker and is in high demand in several countries, because his approach actually
Australian Nuclear Science and Technology Organisation
works.

Workshop Timetable
1345 Workshop commences
1515 Afternoon refreshments and networking break
Why you cannot miss this event:
Followed by the great success of Intelligent Lean Laboratories 2008, the laboratory industry 1730 Closing remarks and end of Day One
has started to actualise the value of Lean principles in laboratory management. Due to its
increased importance, 2nd Annual Lean Six Sigma Laboratories conference will be
focusing on Lean Six Sigma to improve both business (cost & time) and analytical/scientific
(quality) systems in the laboratories.

Lean Six Sigma methodology gives employees a modern, efficient way of getting things
done so they can spend less time managing delays and expectations. That’s why Lean Six Who should attend
Sigma is now being implemented in the laboratories industry-wide.
Chief Scientific Officer (CSO), Vice Presidents, Directors, General Managers, Managers,
2nd Annual Lean Six Sigma Laboratories continues to discuss best practices and case Heads of:
studies of laboratories with dedicated streamed sessions for Heavy Industries and Life • Analytical/ Testing/ Microbiology Laboratory • Quality Assurance
Sciences & FMCGs to better identify and address industry-specific challenges and needs. The • Quality Control/ System • Technical Assurance/ Services
delegates will learn how to tap on the power of Lean and Six Sigma methodologies to • Research & Development • Continuous / Process improvement
improve product quality and turnaround time, with the ultimate aim of achieving greater • Lean Six Sigma leaders • Scientific services
cost reduction, increased operational productivity and competitive advantage.
From the following industries:
• Commercial testing laboratories • Mining and Minerals
• Oil & Gas /Chemicals & Petrochemicals • Heavy Industries
• FMCG/ F&B/ Consumers • Hospitals
marcus evans would like to thank everyone who has helped with the research and
• Government (University, Research Institutions)
organisation of this event, particularly the speakers and their staff for their support and
commitment. • Life Sciences (Pharmaceuticals, Biotechnology and Medical Devices)
 Register Now
Conference Programme Day Two Contact Marketing at marcus evans
Tel +603 2723 6736
Fax +612 9223 2352
Email estherw@marcusevanskl.com
Tuesday 19th May 2009

0830 Morning coffee 1410 Session Six – Case Study

Developing unique work flow and work process approaches to exceed
0900 Opening address form the Chair industry norms for turnaround time, productivity, quality, and cost-
effectiveness
Excellence In Lean Six Sigma Implementation • Benefiting from automation to improve productivity and comply with regulations
• Reducing downtime to maximise utilisation and return-on-investment
0915 Session One – Case Study • Increasing equipment life expectancy and lower overall maintenance costs
Applying Six Sigma style tools and other lean practices to real world David Nielsen Director Automated Laboratory
laboratories to reduce error rates and improve efficiency SA Pathology
• How bad can it get: Case study of old style FMCG lab and lessons learned
• Applying statistical control principles such as 6-sigma and Nordtest to assess test 1450 Session Seven – Panel Discussion
capability and identify high risk procedures and issues Cultivating Lean Six Sigma culture within the organisation through
• Using monitoring tools and proficiency programs in real world laboratories to enhance effective change management
competence • Driving behavioral change of employees to adopt lean six sigma practices
• How to harmonise processes and performance across a multi laboratory/ multi region • Creating greater awareness and highlighting the need to adopt lean six sigma
environment techniques to drive laboratory effectiveness
Eric Wilkes Global Manager Analytical Services • Tailoring a lean six sigma curriculum training programme and certification system to
Fosters Group deliver outstanding results
• How to target lack of focus and lost of interest during the ongoing change
1000 Session Two – Case Study Panellists:
Overcoming the barriers of implementing Lean Six Sigma concepts in Ivy Leung Operations Excellence Expert & Knowledge Manager
laboratories to exceed customer expectations GlaxoSmithKline
• Understanding business needs and stakeholder expectations David Nielsen Director Automated Laboratory
• Identifying improvement opportunities and the approach SA Pathology
• Generating sponsorship Udit Singh General Manager Laboratory Services
• Using DMAIC methodology to change AsureQuality
• Making real difference to the bottom line Eric Wilkes Global Manager Analytical Services
• Building success upon success - depth and breadth Fosters Group
• Creating critical mass - the "Tipping Point"
Dr Ralph Holmes Theme Leader - Iron Ore
Ivy Leung Operations Excellence Expert & Knowledge Manager CSIRO Minerals
GlaxoSmithKline
Lean Six Sigma Blackbelt and GMS Site Director Award in 2007 John McConnell Principal
Wysowl Pty Ltd (Australia)
1045 Morning refreshments &networking break
1520 Afternoon refreshments & networking break
1115 Session Three – Case Study
Embarking on productivity improvement actions to enhance 1600 Session Eight – Case Study
performance Transforming your process from “Push” to “Pull” to keep pace with
demand
• Recognising how to deploy lean six sigma to boost operational productivity from the
laboratories • Implementing Pull to reduce WIP to ensure consistency throughput time
• Examining operational efficiency and inefficiency to identify and address pitfalls • Dealing with volatile demand of customer with systematic ‘pull’ to address the
operation constraint
• Involving and engaging staff in project ownership with Lean Six Sigma application to
address low productivity • Limiting ‘rush’ orders into WIP to increase velocity
• Developing a positive work atmosphere to keep high productivity Gary Pett Process Improvement Manager
NCI Plastics
Udit Singh General Manager Laboratory Services
AsureQuality
Udit has acquired a number of laboratory operations, designed and built a $7M 1640 Session Nine – Case Study
laboratory facility and installed $10M of microbiology automation in their Food Sustaining Lean Six Sigma to ensure long term benefits
Laboratories. Udit has led the commercialisation of the laboratories which have now • Standardising practices in order to keep the system in control
grown to 400 staff in four key locations in New Zealand and Australia. • Enhancing Lean Six Sigma processes by allocating resources and staff with the right
skills
1200 Session Four – Case Study • Creating a viable laboratory infrastructure with Lean Six Sigma techniques
Using lean six sigma for quality control to assure continuous • Making continuous improvement changes when needed to sustain laboratory
improvement performance and quality
• Benchmarking performance against world class standards Michael W McLean Managing Director
• Driving compliance with DMAIC and Lean Six Sigma tools for successful outcomes McLean Management Consultants Pty Ltd
• Using Lean concepts in the laboratory to guarantee reliable results FAICD, FAOQ, CMC, B.Bus., Prod Eng C, Juran Medallist
Dr Rajiv Jayasena Compliance & Improvement Manager
CSL Biotherapies 1730 Closing remarks and close of forum

1245 Networking luncheon

About the Collaborative Partner
1330 Session Five – Case Study
Taking advantage of Lean Six Sigma methodology to deliver
improvements within a challenging economic climate
• Working within a limited budget to deliver exceptional return on investment
• Measuring financial return vs. customer service benefits
• Creative ways to deliver results for little or no investment
Segla is a training and consulting provider dedicated to being the supplier of choice when
Kerri Gill National Business Improvement Manager
it comes to delivering business efficiency solutions utilising Six Sigma, Lean and other
Coca-Cola Amatil
Continuous Improvement methodologies. We work in partnership with our clients, tailoring
our programs to fit their specific needs, enabling us to effectively identify and implement
continuous improvement solutions.

About the Media Partner About the Official Online Media Partner

MedicalSearch is Australia’s leading website for the medical and healthcare sector. Over
65,000 website visitors and 8,500 e-newsletter subscribers use MedicalSearch to find
products, suppliers and current news. MedicalSearch is utilised by medical and B2B advertisers
to promote products, generate sales leads and increase brand awareness among medical
decision makers. Visit www.medicalsearch.com.au or email amanda@medicalsearch.com.au
www.onesixsigma.com is the only information portal, dedicated exclusively to Six Sigma
professionals and activities in Europe. Through the provision of free resources and as a
communication platform for all Six Sigma professionals, onesixsigma.com hosts the most
versatile and powerful improvement technique available to managers today; the sharing of
ideas, knowledge and experiences.