The Lean Game
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After revolutionizing the automobile industry, Lean principles have been successfully applied to different knowledge areas including software development. This workshop is intended to master Lean concepts like Waste, Push&Pull systems, systems thinking,Kaizen etc.! In this interactive game, the participants will work in a small Lego production line, experiencing problems and applying Lean practices to overcome them.
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The Lean Game
- 2. The Lean Game Sneha Kadam @ichsneha ichsneha.blogspot.in
- 3. Why are we here? Ford’s conveyor belt - mass production system “A Bomber an Hour” success Toyota’s lean production system “Just-In-Time” & “Kaizen” success Revolutionised Applied to different manufacturing areas software? I’m here to introduce you to Lean!
- 4. Eliminate Waste fundamental principle of Toyota Production System - Taiichi Ohno “anything that does not add value to the customer is waste” father of TPS Waste aka Muda
- 5. Eliminate Waste fundamental principle of Toyota Production System - Taiichi Ohno 7 Wastes of Manufacturing “anything Inventory that does not add value to the customer Extra processing is waste” Overproduction Transportation father of TPS Waiting Motion Defects - Shigeo Shingo Waste aka Muda Toyota Production System
- 6. Eliminate Waste fundamental principle of Toyota Production System - Taiichi Ohno 7 Wastes of Manufacturing “anything Inventory that does not add value to the customer Extra processing is waste” Overproduction Transportation father of TPS Waiting Motion Identify & eliminate waste Defects - Shigeo Shingo Waste aka Muda Toyota Production System
- 7. Hands On activity Retrospect 3 iterations Work in a Production Line Learn & Core Lean principles Adopt Lean in our world! What are we doing today?
- 8. Lets simulate a production line Station 1 Station 2 Station 4 Station 3
- 9. & build aLego House! & build a House of Lego
- 10. C home-builders B inventory inventory D inventory 2 3 1 4 + QA A inventory E inventory Follow instructions Build houses Sell to the Market Demand i say! “do what i want, not what Cost 1 lego brick = $1 1 house sold for = $25 Hands on : Iteration 1
- 12. Inventory check C inventory Bunch of bricks of B inventory each colour, grouped D inventory by size Bunch of bricks of 1 set of bricks to build each colour house A inventory E inventory Bucket of Lego bricks Nothing.
- 13. Be a QUALITY Do it Worker RIGHT Take PRIDE in the your Work first time!! Stay Motivated!
- 15. Go!
- 16. Stop!
- 17. Lets retrospect! what went well? what went wrong? how can we improve?
- 18. How many un-used Lego bricks? VS houses sold? Measuring Success
- 19. ste w a How many un-used Lego bricks? VS houses sold? Measuring Success
- 20. Predicted Mass Economies market demand production of scale What went wrong?
- 21. Predicted Mass Economies market demand production of scale What went wrong?
- 22. Predicted Mass Economies market demand production of scale What went wrong?
- 23. Push System - upstream information Predicted Mass Economies market demand production of scale “Any colour, as long as it’s black” - Henry Ford What went wrong?
- 24. Push System - upstream information Predicted Mass Economies market demand production of scale failed products! un-used by real-users “it sucked” “people became bored with it! Second life is as mundane as everyday life” ..relating to the software world
- 25. Adaptation On Demand Customer production requirements Learn & Adapt
- 26. Adaptation On Demand Customer production requirements Learn & Adapt
- 27. Adaptation On Demand Customer production requirements “Make only what is needed, only when it is needed, & only in the amount needed” - Kiichiro Toyoda Learn & Adapt
- 28. Pull System - downstream information Adaptation On Demand Customer production requirements “Make only what is needed, hy? only when it is needed, bu t w & only in the amount needed” - Kiichiro Toyoda Learn & Adapt
- 29. Pull System - downstream information Adaptation On Demand Customer production requirements “Make only what is needed, twhy? only when it is needed, b u & only in the amount needed” - Kiichiro Toyoda to build exactly what the market demands to avoid wasted inventory aka aka No Extra features avoid Partially done work ..relating to the software world
- 30. Push System Just-in-Case production - upstream information Predicted Mass Economies market production of scale Just-in-Time production Pull System - downstream information Adaptation On Demand Customer production requirements Pull vs Push Systems
- 31. Pull System - to avoid Overproduction Adaptation On Demand Customer production requirements Kanban 看板 means signboard/card, a signal to aid visual-control. Kanban helps Pull system
- 34. Pull System - to avoid Overproduction Adaptation On Demand Customer production requirements Kanban 看板 means signboard/card, a signal to aid visual-control. Kanban helps Pull system
- 35. C inventory B inventory D inventory station 2 station 3 station 1 + QA station 4 A inventory E inventory implement Pull system Demand comes first Market Demand “do what i want, not what i say! “ Hands on : Iteration 2
- 36. C inventory B inventory D inventory station 2 station 3 station 1 station 4 A inventory E inventory implement Kanban limit WIP i.e. build to fill gaps Pull system Demand comes first Market Demand “do what i want, not what i say! “ Hands on : Iteration 2
- 37. Inventory set-up C inventory 1 set of each colour B inventory D inventory 1 set of each colour 1 set of each colour A inventory E inventory Bucket of Lego bricks Nothing.
- 38. Be a QUALITY Do it Worker RIGHT Take PRIDE in the your Work first time!! Stay Motivated!
- 40. Go!
- 41. Stop!
- 42. Lets retrospect!
- 43. What went well?
- 44. What went wrong?
- 45. Were you constantly working or were idle? Measuring Success
- 46. Were you constantly working or were idle? as te w Measuring Success
- 47. Mura aka Unevenness Some teams worked more while others waited.. ste w a What went wrong?
- 48. clear the bottleneck Goal is levelled process perform multiple tasks (instead of sitting idle) U-shaped work cell (Yatai) Learn & Adapt
- 49. achieve balance of skills Shokjinka generalist vs specialist multi skilled worker Learn & Adapt
- 50. Ready for Dev In Dev In QA (backlog) bug bug ..relating to the software world
- 51. Ready for Dev In Dev In QA (backlog) bug bug ..relating to the software world
- 52. Aids visual Ready for Dev In Dev In QA control 5 4 2 bug bug Limit WIP Signals demand pull system ..relating to the software world
- 53. Ready for Dev In Dev In QA 5 4 2 bug bug ..relating to the software world
- 54. dev, playing a qa when need arises Ready for Dev In Dev In QA 5 4 2 bug bug ..relating to the software world
- 55. C inventory B inventory D inventory station 2 station 3 station 1 station 4 A inventory E inventory Market Demand “do what i want, not what i say! “ implement Work Cell & self - organise Signal when you finish a house Hands on : Iteration 3
- 56. Build quality in! -Think about- levelling the workload Quality is everybody's responsibility!
- 58. Inventory set-up C inventory Bucket of Lego bricks B + D inventory house specs inventory Bucket of Lego bricks Bucket of Lego bricks + + house specs house specs A inventory E inventory Bucket of Lego bricks + Nothing. house specs
- 59. Be a QUALITY Do it Worker RIGHT Take PRIDE in the your Work first time!! Stay Motivated!
- 61. Go!
- 62. Stop!
- 63. Lets retrospect! what went well? what went wrong? how can we improve?
- 64. How many houses did we sell? Measuring Success
- 65. Jidoka intelligent automation Stop the production line, to build quality in! Quality Assurance
- 66. Jidoka to raise productivity ke -yofing on oka proo P ror a nd Er Stop automatically if anything irregular occurs di ng oi Av ste Never produce defects wa Build it RIGHT the first time
- 67. andon Quality Assurance, in our world
- 68. simple tools to build quality in Go and See Analyse the situation One-piece flow & andon Ask 5 “Whys” Quality Assurance
- 69. Muda aka Waste 7 Wastes of Manufacturing Inventory Extra processing Overproduction Transportation Waiting Motion Defects - Shigeo Shingo Muda Toyota Production System
- 70. Muda aka Waste 7 Wastes of Manufacturing 7 Wastes of Software development Inventory Partially done work Extra processing Gold plating Overproduction Extra Features Transportation Task switching Waiting Waiting Motion Motion Defects Defects - Shigeo Shingo - Mary Poppendick Muda in our world Toyota Production System Lean Software Development
- 71. Thank you @ichsneha ichsneha.blogspot.in http://www.youtube.com/watch?feature=player_embedded&v=24PH9OCe4C8
- 72. The Lean Game Sneha Kadam @ichsneha ichsneha.blogspot.in
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