Not long ago I accompanied my wife on a business trip to Washington, D.C. While she was attending her conference, I took in some of the sites in our nation’s capital. One tour I’ve always wanted to take was through the Bureau of Engraving and Printing (BEP). As I visited the bureau, the guide mentioned that the BEP was utilizing Lean Six Sigma (LSS) techniques in a variety of ways. It was interesting to hear how they are saving while making (i.e., printing) money.
In fact, their LSS project portfolio is growing by leaps and bounds. BEP has more than 20 active LSS and 5S projects in progress, the most BEP has ever had at one time; and more than 100 are planned for future completion. BEP continues to aggressively implement 5S methodology as part of the overall LSS program initiatives deployment. 5S is a LSS tool that stands for Sort, Straighten, Shine, Standardize and Sustain. 5S efforts improve workplace efficiency and throughput by standardizing working practices and by removing variability from operational processes to provide improved product quality and customer service.
One of the most fascinating uses of LSS, though, was in BEP’s Mutilated Currency Division (MCD). From burned bills torched in a devastating wildfire to soggy savings water damaged after being found in a box in the backyard, a team of trained professionals is dedicated to helping people redeem their mangled money. They process more than 20,000 claims each year totaling more than 40 million worth of damaged U.S. currency as a free public service.
How is it possible? All the examiners have to do is verify that the scraps really were cold hard cash at one time. If they identify at least 51 percent of a bill, the Treasury will replace it.
The examination process is rigorous and time consuming, and although the MCD works very hard to complete claims as quickly as possible, the processing times can vary from six months to more than two years. In order to address this, the MCD applied LSS methodologies to remove waste, redundant process steps, and systemic variation. The MCD completed a renovation of the examiner rooms, lab room, hallways, new examiner tables complete with air extraction units and new lighting, increased camera coverage, and refurbished two vaults. In addition, process mapping was used to document and display the entire process to identify and eliminate non-value added process steps. The project resulted in process times improving up to 75% faster for completion.
The Bureau has figured out how to save money while saving money – literally! So when your life savings gets torched in a house fire or your dog eats your wallet, there’s a roomful of really smart, efficient people in Washington, D.C. who may be able to help you. Check out these tips on how to reclaim your cold, hard cash!
How are you helping your employees to work smarter by reducing the amount of time they spend on non-productive activities and correcting errors? If your business processes need a “check-up,” please email me at michael@leadingchangeforgood.com! I’d love to help you get back to a healthy, productive workplace.
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