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Lean Lego Game

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by

Kathy Chung

on 15 May 2014

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Transcript of Lean Lego Game

Lean Lego Game
Why are we here?
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?
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
...
Agenda
Intro
Simulating a production line
Experiment #1
Simulate a production line
Examples of Lean
Push and Pull Systems
Kanban
Systems Thinking
Flow
The list goes on
4 teams
4 rounds of 40 seconds
Follow the instructions
Build houses
1 piece = $1
1 house = $25
Houston...
What went wrong?
Waste
Visible Inventory
Over/Under production
Seven Wastes
Overproduction
Waiting
Unnecessary transportation
Over-processing
Inventory
Motion
Defects
Push and Pull Systems
Push System = upstream information
Pull System = downstream information
Expected Demand
Mass Production
Economies of Scale
Customer Requirements
On Demand
Production
Adaptation
Physical device
Signals demand to downstream processes
Regulates demand on a pull system
Limits Work in Progress (WIP)
Aids visual control
Self directing
Kanban
Experiment #2
Using Pull and Kanban
Set up minimum buffers at intermediate steps
Demand comes first
Items are produced to fill gaps in the buffers
4 rounds of 40 seconds
Unleveled Process
Another type of waste
Some people working more than other
Mura (Unevenness)
FLOW!
Final goal is a leveled process
Production line must be a continuous flow
One piece is bought when one piece is delivered
Sustainable pace
Systems Thinking
Why does it still feel wrong?
What are other teams doing?
What’s the purpose of the system?
A bad system will beat a good person every time

~ W. Eduards Deming
Let's get crazy!
Do we need 4 teams to build a house?
Teams 1 and 2 have overlapping tasks
Yatai (work cell)
Multi-skilled worker
Single piece flow
Experiment #3
Using work cells
Each person builds a house
Round of 160 seconds
Signal (raise your hand) if you finish your house
Kaizen
Continuous Improvement
Reflect and adapt
Learn by standardizing
Long term thinking
Respect People
It's your turn!
How do we improve the process?
Experiment #4
Discuss your own process
1 round for each team
Is that it?
We saw some practices
Practices are contextual
Underlying principles must be understood
Okay, so what's Lean?
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
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
FALSE
REALITY
Task 1
PROFIT!
Task 4
Task 3
Task 2
AAHCAHCAMMAN
2 weeks
v1.5
Lean in Software Development
Knowledge flow is not the same as material flow
Manufacturing is not the same as software development
Lean Product Development
Lean Wastes in Software Development
Extra features
Waiting
Unnecessary transportation
Gold Plating
Partially Completed Work
Unnecessary Movement
Defects
Unused Employee Creativity
Overproduction
Waiting
Unnecessary transportation
Overprocessing
Inventory
Motion
Defects
THANKS FOR PARTICIPATING!

ANY QUESTIONS?
BREAK
Handoffs
Full transcript