1. Building
the
Millennium
Falcon
A
Lean
so5ware
development
case
study

2. WHO
AM
I?

4. XP
Coach
Senior
Engineer
Your
story
teller

5. Agenda
Lego
Star
Wars
A
lean
approach

6. Recap
on
Lego

7. Recap
on
Star
Wars
Episodes
1-­‐3:
We
don’t
really
talk
about
them
Episode
4:
Boy
realises
he
can
do
magic,
falls
in
love
with
girl,
sHcks
it
to
the
evil
empire
Episode
5:
Boy’s
mate
gets
frozen,
boy
learns
how
to
*do*
magic,
finds
out
his
Dad
runs
the
evil
empire.
Episode
6:
Boy
understands
he
loves
the
girl
as
a
sister
<phew>,
boy
fights
Dad,
Dad
fights
boy,
boy
beats
Dad,
old
cackling
guy
fights
boy.
Dad
beats
old
cackling
dude.
Cut
to
party.
All
clear
now?

8. Recap
on
Lean
A
philosophy
that
enables
moHvated
people
to
build
the
right
stuff
for
the
right
customers
at
the
right
Hme
(me)
(Your
definiHon
may
vary)

9. Now…
Witness
the
firepower
of
this
fully
operaHonal
conference
talk

10. office
A long time ago, in a galaxy far,
far, away… ^

11. Lean
Lego

12. Episode 4
A
NEW
BOX

15. 300
double-­‐sided
pages

16. >
5000
pieces

17. James
Alex
Seema
Alex
Andy

18. The
science
bit…

19. A
Story
Wall

20. Swim
lanes

21. Ready
for
development

22. A
burn-­‐up
chart

23. A
cumulaHve
flow
chart

24. 3d 1.5d 0.5d
2d 10d 30d
Activity Activity Activity
A
value
stream
map

25. A
control
chart

26. Episode 5
THE
LEGO
STRIKES
BACK

27. We
took
a
look
at
the
first
set
of
instrucHons…

28. …
and
all
piled
in
to
the
box

29. …
then
we
all
put
the
bits
together

30. It
went
really
slowly…

31. See?
10 mins 5 mins
1 min
Finding
Pieces Assembling
for Step pieces

32. Tip
1
Understand
the
system
you
are
working
in

33. Turns
out
shared
state
isn’t
that
effecHve
here…
Pieces being Pieces being
Backlog found assembled Done

34. Turns
out
shared
state
isn’t
that
effecHve
here…
Pieces being Pieces being
Backlog found assembled Done

35. Turns
out
shared
state
isn’t
that
effecHve
here…
Pieces being Pieces being
Backlog found assembled Done

36. Turns
out
shared
state
isn’t
that
effecHve
here…
Pieces being Pieces being
Backlog found assembled Done

37. Turns
out
shared
state
isn’t
that
effecHve
here…
Pieces being Pieces being
Backlog found assembled Done

38. Tip
2
Use
Kanban
/
story
walls
to
visualise
your
system

39. the
result
of
all
this?

40. Complete
Half way
through
0
Heat
opened End day Cows hell
pigs fly death of
the box 1 come freezes
the
home
Universe

41. L

42. Episode 6 pr ocess
THE
RETURN
OF
THE
JEDIS
^

43. A
funny
thing
happened
next…
Finding
Pieces Assembling
for Step pieces

44. We
moved
from
this:
Everybody
doing
this
Finding
Pieces Assembling
for Step pieces
followed
by

45. To
this:
Some
people
Some
people
doing
this
doing
this
Finding
Pieces Assembling
for Step pieces
At
the
same
Hme
as

46. See?

47. The
constraint
was
idenHfied
10 mins 5 mins
1 min
Finding
Pieces Assembling
for Step pieces

48. And
elevated…
Pieces being Pieces being
Backlog found assembled Done
…turns
out
you
can
find
pieces
in
parallel

49. Tip
3
Use
the
Theory
of
Constraints:
IdenHfy
and
Eliminate

50. Remember
what
Mary
Poppendieck
said
about
Queues..?

51. This
started
to
happen…

52. We
added
a
queue
Pieces being Pieces ready Pieces being
Done
Backlog found for assembly assembled
based
on
the
pages
in
the
manual

53. The
folks
assembling
pieces
pulled
from
the
queue
Pieces being Pieces ready Pieces being
Done
Backlog found for assembly assembled

54. The
folks
finding
pieces
pushed
into
the
queue
Pieces being Pieces ready Pieces being
Done
Backlog found for assembly assembled

55. Tip
4
Introduce
queued
states
into
your
system
to
help
visualise
bohlenecks

56. And
we
got
faster

57. 300
266
233
200
166
# pages
133
100
66
33
0
4 8 12 16 20 24 28 32 36 40 44 48
# hours

58. Tip
5
Use
burn-­‐up
charts
and
yesterday’s
weather
to
track
progress

59. But
it
didn’t
stop
there

60. The
team
became
T-­‐Shaped
Breadth of knowledge
Depth of experience

61. Specialists
in
Specialists
in
assembling
finding
pieces

62. and
those
specialists
noHced
this…
9
8
length of time to find a piece
7
6
5
4
3
2
1
0
time

63. Finding
a
piece
is
a
funcHon
of
piece
size
and
the
total
number
of
that
type
of
piece
available
than
this
This
takes
longer

64. so
we
did
this…

65. length of time to find a piece
1
6
2
3
7
4
9
5
8
0
time

66. Tip
6
Use
control
charts
to
visualise
variability
And
then
work
to
reduce
it

67. There
were
other
interesHng
things
happening
too

68. We
used
defects
tracking…

69. And
work
in
progress
limits…
Pieces being Pieces ready Pieces being
Done
Backlog found for assembly assembled
Max
4

70. And
we
swarmed
around
bohlenecks
Pieces being Pieces ready Pieces being
Done
Backlog found for assembly assembled

71. Tip
7
Limit
WiP
and
then
pull
more
work
from
*up
stream*
if
you
are
blocked

72. …

73. 300
266
233
200
166
# pages
133
100
66
33
0
4 8 12 16 20 24 28 32 36 40 44 48
# hours

75. J

76. Summary
Understand
your
system
–
use
systems
thinking
tools
Visualise
work
using
kanban
boards
/
story
walls
Work
to
eliminate
constraints
in
your
system,
use
the
Theory
of
Constraints
Work
in
Progress,
Swarming
helped
keep
throughput
high
Yesterdays
weather
and
burnup
Use
control
charts
to
idenHfy
and
reduce
variability

77. And
finally
This
actually
happened
We
spent
nearly
6
weeks
(on
and
off)
building
it
The
team
was
completely
self-­‐organising
No
one
was
telling
us
how
to
do
this,
it
just
happened
this
way
Why
did
it
happen
this
way?
10,000
hours?
Combined
>
50
years
of
experience
working
with
‘agile’?

78. Thanks!
jalewis@thoughtworks.com
Bovon.org
@boicy