Lean Lego Game

It's your turn!

Lean Lego Game

Experiment #1

Examples of Lean

How do we improve the process?

Simulate a production line

• 4 teams
• 4 rounds of 40 seconds

• Push and Pull Systems
• Kanban
• Systems Thinking
• Flow
• The list goes on

Agenda

Lean?

• Follow the instructions
• Build houses
• 1 piece = $1
• 1 house = $25

Experiment #4

• Intro
• Simulating a production line

Task 4

Experiment #3

Toyota Production System

• Revolutionized manufacturing (Ford vs. Toyota)
• Started to be applied in different areas
• Google, Dell, Zara
• Product Development
• Supply Chain Management
• Software
• Healthcare
• ...

• Discuss your own process
• 1 round for each team

• Using work cells
• Each person builds a house
• Round of 160 seconds
• Signal (raise your hand) if you finish your house

Why are we here?

Houston...

Seven Wastes

What went wrong?

Handoffs

• Overproduction
• Waiting
• Unnecessary transportation
• Over-processing
• Inventory
• Motion
• Defects

• Kathy’s making us
• Legos are fun
• Lean concepts are being used in the software world
• BUT not everyone has had contact with Lean principles and practices

Lean in Software Development

Kaizen

BREAK

• Manufacturing is not the same as software development
• Lean Product Development

• Knowledge flow is not the same as material flow

Push and Pull Systems

• Continuous Improvement
• Reflect and adapt
• Learn by standardizing
• Long term thinking
• Respect People

Waste

Push System = upstream information

Mass Production

Expected Demand

Economies of Scale

Pull System = downstream information

Experiment #2

• Visible Inventory
• Over/Under production

Adaptation

On Demand

Production

Customer Requirements

Systems Thinking

• Using Pull and Kanban
• Set up minimum buffers at intermediate steps
• Demand comes first
• Items are produced to fill gaps in the buffers

AAHCAHCAMMAN

• 2 weeks
• v1.5

Is that it?

• Why does it still feel wrong?
• What are other teams doing?
• What’s the purpose of the system?

• 4 rounds of 40 seconds

Kanban

• We saw some practices
• Practices are contextual
• Underlying principles must be understood

Unleveled Process

A bad system will beat a good person every time

~ W. Eduards Deming

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

• Another type of waste
• Some people working more than other
• Mura (Unevenness)

FLOW!

Lean Wastes in Software Development

Okay, so what's Lean?

Let's get crazy!

FALSE

REALITY

Yatai (work cell)

• Final goal is a leveled process
• Production line must be a continuous flow
• One piece is bought when one piece is delivered
• Sustainable pace

• Overproduction
• Waiting
• Unnecessary transportation
• Overprocessing
• Inventory
• Motion
• Defects

• Extra features
• Waiting
• Unnecessary transportation
• Gold Plating
• Partially Completed Work
• Unnecessary Movement
• Defects
• Unused Employee Creativity

• Tangible recipe for success
• Management project or program
• Set of tools for implementation
• System for production floor only
• Implementable in a short- or mid- term period

THANKS FOR PARTICIPATING!

ANY QUESTIONS?

• Multi-skilled worker
• Single piece flow

• Consistent way to think
• Total management philosophy
• Focus on total customer satisfaction
• Environment of teamwork and improvement
• Never ending search for a better way
• Quality built in process
• Evolutionary

• Do we need 4 teams to build a house?
• Teams 1 and 2 have overlapping tasks