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    The Lean Lego Game Slides Short iSixSigma PDF

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    Alvaro Robles
    The document describes a hands-on simulation game to teach Lean principles. It discusses setting up a simulated production line with multiple tasks and teams to build houses. Players experience problems with push systems and waste. The game then introduces concepts like pull systems using Kanban, balancing work with Heijunka, multitasking with work cells, and continuous improvement. Finally, it discusses how Lean principles can be applied to software development processes rather than just manufacturing.

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    The Lean Lego Game Slides Short iSixSigma PDF

    Uploaded by

    Alvaro Robles
    162 views37 pages
    The document describes a hands-on simulation game to teach Lean principles. It discusses setting up a simulated production line with multiple tasks and teams to build houses. Players experience problems with push systems and waste. The game then introduces concepts like pull systems using Kanban, balancing work with Heijunka, multitasking with work cells, and continuous improvement. Finally, it discusses how Lean principles can be applied to software development processes rather than just manufacturing.

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    The-Lean-Lego-Game-Slides-Short-iSixSigma.pdf

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    The document describes a hands-on simulation game to teach Lean principles. It discusses setting up a simulated production line with multiple tasks and teams to build houses. Players experience problems with push systems and waste. The game then introduces concepts like pull systems using Kanban, balancing work with Heijunka, multitasking with work cells, and continuous improvement. Finally, it discusses how Lean principles can be applied to software development processes rather than just manufacturing.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    162 views37 pages

    The Lean Lego Game Slides Short iSixSigma PDF

    Uploaded by

    Alvaro Robles
    The document describes a hands-on simulation game to teach Lean principles. It discusses setting up a simulated production line with multiple tasks and teams to build houses. Players experience problems with push systems and waste. The game then introduces concepts like pull systems using Kanban, balancing work with Heijunka, multitasking with work cells, and continuous improvement. Finally, it discusses how Lean principles can be applied to software development processes rather than just manufacturing.

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    You are on page 1of 37

    The Lego Lean Game

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Agenda
    •  Quick introduction
    •  Simulating a production line
    Hands  On  

    Debriefing  

    •  How about software? Results  

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Why are we here?
    •  Lean concepts starting to be noticed in the
    software world
    •  But not everyone has had contact with
    Lean principles and practices

    We’re here to introduce you to Lean


    Hands On!

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Lean?
    •  Toyota Production System
    –  Revolutionized manufacturing (Ford vs.
    Toyota)
    –  Started to be applied to different areas
    •  Google, Dell, Zara, …
    •  Product Development
    •  Supply Chain Management
    •  Health Care
    •  Software
    •  …

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Lean?

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    What we want to show
    •  Push and Pull Systems
    •  Kanban
    •  Systems Thinking
    •  Flow
    •  Heijunka
    •  Yatai (Work Cell)
    •  And more…

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Hands On – 1 st Step
    •  Let’s simulate a production line…

    Task  1   Task  2   Task  3   Task  4   Sell  house  

    •  4 Teams •  Follow the instructions


    •  4 rounds of 30 seconds •  Build houses
    (x2) •  1 Piece = $ 1.00
    •  1 House = $ 25.00

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Stay Motivated!

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Houston we have a problem…

    What went wrong?

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Waste
    •  Visible
    Inventory
    •  Over/Under
    Production

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    7 Wastes of Manufacturing
    •  Overproduction
    •  Waiting
    •  Conveyance
    •  Overprocessing
    •  Inventory
    •  Motion
    •  Defects

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Push and Pull Systems

    •  Push System – upstream information

    Expected   Mass   Economies  


    Demand   ProducCon   of  Scale  

    •  Pull System – downstream information

    On  Demand   Customer  
    AdaptaCon  
    ProducCon   Requirements  

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Kanban
    •  Physical device
    •  Signals demand to downstream
    processes
    •  Regulates demand on a pull system
    •  Limits Work in Process (WIP)
    •  Aids visual control
    •  Self-directing

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Kanban

    Step  1   Step  2   Step  3  


    Task  1   Task  3   Task  5  

    Task  2   Task  5  
    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
    Kanban

    Step  1   Step  2   Step  3  


    Task  1   Task  3   Task  5  

    Task  2   Task  5  
    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
    Hands On – 2 nd Step
    •  Using Pull and Kanban
    –  Setup minimum buffers at intermediate steps
    –  Demand comes first
    –  Items are produced to fill gaps in the buffers

    Sell  house   Task  4   Task  3   Task  2   Task  1  

    •  4 rounds of 30 seconds (x2)


    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
    Stay Motivated!

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Houston we have a problem…

    What went wrong?

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Unleveled Process
    •  Another type of waste
    •  Some people working more than others
    •  Mura (Unevenness)
    •  Heijunka

    Balance number of people based on


    constraints

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Systems Thinking
    •  Why does it still feel wrong?
    •  What are the other teams
    doing?
    •  What’s the purpose of the
    system?
    •  Do we need 4 teams to
    build a house?
    •  Teams 1 and 2 have
    overlapping tasks

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Systems Thinking
    •  Why does it still feel wrong?
    •  What are the other teams
    doing?
    •  What’s the purpose of the
    system?
    •  Do we need 4 teams to
    build a house?
    •  Teams 1 and 2 have
    overlapping tasks

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Yatai (Work Cell)
    •  Multi-skilled worker
    •  Single piece flow

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Hands On – 3 rd Step
    •  Using Work Cells
    –  Each group will build 4 houses
    –  Each person builds the whole house
    –  Signal when all houses are built

    Sell  house   Build!  

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Stay Motivated!

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Kaizen
    •  Continuous Improvement
    •  Reflect and adapt Plan   Do  

    •  Learn by standardizing
    Act   Check  
    •  Long term thinking
    •  Respect People

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Hands On – 4 th Step

    It’s your turn to help


    ?   us improve the
    ?   process

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Stay Motivated!

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Our Results

    Push  System  

    Kanban  

    Yatay  

    Team’s  Process  

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Is That All?
    •  We saw some of the practices
    •  Practices are contextual
    •  Underlying principles must be understood
    –  Like agile!

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Is That All?
    Myth   Reality  
    What  TPS  Is  Not   What  TPS  Is  
    A  tangible  recipe  for  success   A  consistent  way  of  thinking  
    A  management  project  or  program   A  total  management  philosophy  
    A  set  of  tools  for  implementaCon   Focus  on  total  customer  saCsfacCon  
    A  system  for  producCon  floor  only   An  environment  of  teamwork  and  
    improvement  
    Implementable  in  a  short-­‐  or  mid-­‐   A  never  ending  search  for  a  beWer  
    term  period   way  
    Quality  built  in  process  
    EvoluConary  

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Lean in Software Development
    •  Manufacturing is not the same as Software
    Development
    •  Lean Product Development
    –  Knowledge flow is not the same as material
    flow

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Lean in Software Development
    •  7 Wastes in Software
    –  Extra Features
    –  Waiting
    –  Unnecessary Transportation
    –  Gold Plating
    –  Partially Completed Work
    –  Unnecessary Movement
    –  Defects
    –  Unused Employee Creativity
    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
    Lean in Software Development
    •  Example: Push System in Software

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Lean in Software Development
    •  Example: Pull System in Software

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Lean in Software Development
    •  Example: Pull System in Software

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Lean in Software Development
    •  Much more:
    –  Eliminate Waste
    –  Create Knowledge
    –  Build Quality In
    –  Defer Commitment
    –  Deliver Fast
    –  Respect People
    –  Improve System

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.


    Thank you!

    Questions?

    THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.

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