the lean experience factory simulation - materials

The Lean Experience

Factory simulation - materials

The Lean Experience

Factory simulation - materials

Checklist – Factory simulation materials

• Templates folder

• Circuit boards – 120 (3 rounds X 15 orders X 2 sheets/order + 30% buffer + 5 sheets for round 4)

• 7 packets of dots – 2 Green, 2 Blue, 2 Red, 1 White – 1,000 each colour (3 rounds X 15 orders X 50 dots +30% buffer + 30 for round 4)/3 colours

• Box – 4 scissors, 5 stopwatches, 1 caliper, discs

• Dice – 2 customer, 20 standard dice

• Changeover timers

• Maintenance toolboxes (2)

• Paper cutter

• DVD’s – Creating a Lean Culture and What Lean Means

Checklist – round 1Customer• Label• Work instruction• 2 dice• Stopwatch• Customer order log sheet

Production Control• Label• Work instruction• Post-it notes• Prod Cont order log sheet

Warehouse• Label• Work instruction• Circuit boards• Nano dots

Fusing• Label• Work instruction• 2 dice• 2 orange changeover timers

Laser Cutting• Label• Work instruction• 2 green scissors• 2 dice• 2 black changeover timers

Sorting• Label• Work instruction

Shipping• Label• Work instruction

Maintenance• Label• Work instruction• Maintenance toolbox• 2 stopwatches• Maintenance log sheet

Quality• Label• Work instruction• Quality log sheet

Continuous Improvement• Label• Work instruction• 2 stopwatches• CI observation sheet

Material handling• Label• Work instruction

Plant manager• Label• Work instruction

Checklist – round 3

Customer• Work instruction• 2 dice• Stopwatch• Customer order log sheet

Production Control• Work instruction• WIP storage labels (3)• FG storage labels (3)

Warehouse• Work instruction• Circuit boards• Nano dots• POUS labels (4)

Fusing• Work instruction

Laser Cutting• Work instruction• 2 blue scissors

Shipping• Work instruction

Maintenance• Work instruction• Maintenance toolbox• 2 stopwatches• Maintenance log sheet

Quality• Work instruction• Quality log sheet

Continuous Improvement• Work instruction• 2 stopwatches• CI observation sheet

Material handling• Work instruction

Plant manager• Work instruction

Checklist – round 4

Customer• Work instruction• 2 dice• Stopwatch• Customer order log sheet

Production Control• Work instruction• FG storage labels (1)

Warehouse• Work instruction• Circuit boards• Nano dots• POUS labels (4)

Fusing• Work instruction

Laser Cutting• Work instruction• 2 blue scissors

Shipping• Work instruction

Maintenance• Work instruction• Maintenance toolbox• 2 stopwatches• Maintenance log sheet

Quality• Work instruction• Quality log sheet

Continuous Improvement• Work instruction• 2 stopwatches• CI observation sheet

Material handling• Work instruction

Plant manager• Work instruction

Template checklist – round 1

Role Std work

Log sheet Other

Customer 1 1

Warehouse 1

Production Control

1 1

Fusers 2

Laser Cutters 2

Sorters 2

Material handlers 2

Shipping 1

Maintenance 1 1

Quality 1 1

Continuous Improv

1 1

Plant Manager 1


Role Std work

Log sheet

Other

Customer Same R1 1

Warehouse 1 POUS – 2 Circuit boards, 2 Nano dot

Production Control

1 2 WIP storage, 2 FG storage

Fusers 2 Fusing error proofing templates

Laser Cutters 2

Material handlers 1

Shipping 1

Maintenance 1 1

Quality 1 1 Quality standards

Continuous Improv

1 1

Plant Manager 1


Role Std work

Log sheet

Other

Customer Same R1 1

Warehouse 1 POUS – 2 Circuit boards, 2 Nano dot

Production Control

1 1 FG storage

Fusers 2

Laser Cutters 2

Material handlers 1

Shipping 1

Maintenance 1 1

Quality Same R3 1 Quality standards

Continuous Improv

Same R3 1

Plant Manager Same R3

Data sheet checklistTitle Quantity

Customer order log sheet 4

Prod Cont order log sheet 4

Maintenance log sheet 4

Quality log sheet 4

CI observation sheet 4

Customer

Customer work instructionsPurpose• As the customer, you will place an order every minute for 15 minutes.• You expect “on time” delivery (note 1 below) and 100% quality (note 2).

Materials• A stopwatch to time the orders & delivery.• 2 large dice to roll for orders + 6 coloured dots and 6 white dots (refer notes 4 & 5).• Customer order log sheet to record the orders, delivery times and any quality issues.

ProceduresOrders1. Announce the start of the round.2. Roll the 2 dice to determine the order (note 3 & 4)3. Tell the Production Controller the order4. Record the time, type & quantity on the “Order log sheet”5. Repeat steps 2-4 exactly one minute apart until the round is complete one minute after the 15th order.6. Announce the end of the round.Deliveries1. When a delivery is received, check for the correct delivery (note 1) and quality (note 2). If all is correct,

record the time of delivery and calculate the lead time. If the delivery or quality is not correct, reject the whole delivery and record reasons on the “Order log sheet”.

2. For repeat delivery or quality problems, express your displeasure to the Production Control person. If this does not work, elevate your concerns to the Plant Manager.

Notes1. A delivery with the correct product type and quantity received within a minute of placing the order is

considered “on time”. Deliveries must be received in the sequence in which they were ordered. Deliveries received out of sequence are to be rejected.

2. Good quality is a full nano dot with no visible damage. If any damaged or missing (blank square) nano dots are found, the whole order is rejected.

3. Do not communicate these requirements to your supplier unless directly asked.4. Product type die – coloured dots on the die indicate the product type. Change the product mix for each

round, e.g. R1 2G2B2R, R2 1G3B2R, R3 2G1B3R, R4 3G2B1R (each combination must have at least one of the three product colours).

5. Quantity die – use white dots with the following numbers for each round R1 – 4X50, 1X75, 1X25; R2 – same as round 1; R3 – 40, 45, 50, 50, 55, 60; R4 – Quantity dice not used.

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Customer order log sheetRound No. ______

No. TypeE,CO2,

H2O

Qty Order time

Delivery time

Lead time

(Del – Ord)

Delivery or quality issues

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Raw materialswarehouse

Warehouse work instructionsRound 1Purpose• As the warehouse store person, you store the raw materials and fill orders from Production Control.

Materials• Circuit boards• Nano dots – 3 types: Green CO2, Blue H2O, Red E.

Procedures1. Receive the customer order from Production Control.2. Pick the required raw materials for the order.3. Contact the Material Handler and ask them to deliver the raw materials to the start of production

(Fusing).

Notes1. Your boss is Production Control. Do not release raw materials from the warehouse without a

customer order from Production Control.2. You provide excellent service to Future Solutions Enterprise and carry inventory a large inventory of

raw materials to make sure production never runs out.

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Warehouse work instructionsRound 3Purpose• As the warehouse store person, you store the raw materials and fill orders from Production Control.• To reduce wasted motion by operators, you have implemented point of use storage at the Fusing

operation for nano dots and circuit boards.• As circuit boards take up a lot of space, you have determined that you will keep only 5 at the Fusers’

workstation. These will be replenished as used.• To reduce waste in the Cutting operation, the supplier of the circuit boards has been requested to supply

the grid area only, without the waste around the edges.

Materials• Circuit boards• Nano dots – 3 types: Green CO2, Blue H2O, Red E.• Paper cutter.• 2 laminated point of use storage locators for circuit boards.• 2 laminated point of use storage locators for nano dots• Masking tape.

ProceduresSet up prior to start of round1. Cut out the grids on the circuit boards and dispose of the waste around the edges so that only the usable

grid is supplied.2. Layout laminated sheets for point of use storage locations at the Fusers’ workstation (secure with tape).3. Fill the point of use storage locations with materials.

During the round1. Prepare more cut out circuit boards as required. 2. Monitor usage of the circuit boards and replenish as required (keeping the inventory at point of use to 5).3. Work with the material handler to make sure the Fusers do not run out of raw materials.

Notes1. The material handler will deliver the circuit boards to the Fusers.

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Fuser 1 - storage area for circuit boards (R3)

Max 5

Fuser 1 - storage area for nano dots


Max 5

Fuser 2 - storage area for nano dots

Warehouse work instructionsRound 4Purpose• As the warehouse store person, you store the raw materials and fill orders from Production Control.• The point of use storage and replenishment system is the same as used in round 3.• The Fusing and Laser Cutting processes have been improved to incorporate continuous flow. The

supplier of the circuit boards has made a change to supply these in single strips of 10.

Materials• Circuit boards• Nano dots – 3 types: Green CO2, Blue H2O, Red E.• Paper cutter.• 2 laminated point of use storage locators for circuit boards.• 2 laminated point of use storage locators for nano dots (same as round 3).• Masking tape.

ProceduresSet up prior to start of round1. Cut up 20 sheets into single strips of 10 squares using the paper cutter.2. Provide the boxes of nano dots and 10 strips to the Fusers (5 each).

During the round1. Monitor usage of the strips and replenish as required (keeping the inventory at point of use to 5 per

Fuser).2. Work with the material handler to make sure the Fusers do not run out of raw materials.

Notes1. The material handler will deliver the circuit boards to the Fusers.

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Max 1 strip

Max 1 strip

Max 1 strip

Max 1 strip

Max 1 strip

ProductionController

Prod. Cont. order log sheetRound No. ______

No. TypeE,CO2,H2O

Qty Delivery or quality issues

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Production controller work instructionsRound 1Purpose• As the Production Controller, you will schedule production of orders through the factory.• You are also responsible for ordering raw materials from the supplier and delivering them to

production.

Materials• Post-it notes and pen for recording orders.• Prod. Cont. order log sheet.

Procedures1. Receive the order from the customer.2. Record the order (Order no, type, quantity) on a post it note and the Prod Cont order log sheet.3. Give the order to the warehouse to deliver raw materials required to start of production.4. Monitor the progress of the order to make sure the order remains with the work as it progress through

the factory so that the complete order is delivered to the customer in the correct sequence.5. Record details on the Prod Cont order log sheet.

Notes1. The warehouse store person and the material handler work for you.2. Production control delivers and monitors orders but does not move materials (ie circuit boards, nano

dots or work in progress). This is the job of the material handler.3. Production control is the first point of contact for the customer for delivery or quality issues. Work

with the production people and support people to help resolve any issues.

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Production controller work instructionsRound 3Purpose• As the Production Controller, you have worked with the production people to establish kanban pull

systems.• To ensure supply, you have installed point of use storage for raw materials and a kanban system with

the Supplier.

Materials• Laminated product storage locations: 3 between Fusing and Laser Cutting; 3 finished product storage

ProceduresSet up of kanban systems1. Prior to the start of round 3, set up the kanban system by placing the WIP storage templates between

Fusing and Cutting and the FG storage template after Laser Cutting.

During the round• Monitor the inventory levels.• No need to record production orders.

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WIP storage after Fusing (R3)

Max 2

Finished goods storage (R3)

5 per square

FIFO flow

55 45 35 25 15 5

60 50 40 30 20 10

102030405060

Production controller work instructionsRound 4Purpose• As the Production Controller, you have worked with the production people to establish kanban pull

systems.• To ensure supply, you have installed point of use storage for raw materials and a kanban system with

the Supplier.

Materials• 1 laminated finished product storage location.

ProceduresSet up of kanban systems1. Prior to the start of round 4, set up the kanban system by placing the FG storage template after Laser

Cutting.

During the round• Monitor the inventory levels.• No need to record production orders.

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Finished goods storage (R4)

Max 1 Max 1 Max 1

Max 1 Max 1 Max 1

Fusers

Fusers’ work instructionsRound 1Purpose• To fuse the nano dots to the circuit boards

Materials• Circuit boards & nano dots• 2 orange changeover timers• 2 downtime dice

Procedures1. The circuit boards and nano dots required for each order are delivered by the material handlers.2. Place the nano dots on the circuit boards in the configuration shown below.3. When the order is complete, notify the material handler to collect the order.4. When changing between different products, turn over the orange changeover timer, wait for the changeover to take place (when

the sand runs out), then proceed with production.5. When every 3rd order is received, before starting production, roll the downtime dice and take the action below depending on

what number is rolled:1. Equipment failure – call maintenance and tell them you need a 1/8” X 3/4” nut & bolt. Wait till received.2. You are concerned about running out of parts in the warehouse. Go and question the store person.3. Equipment failure – call maintenance and tell them you need a 3/16” X 1/2” nut & bolt. Wait till received.4. You are concerned about what you will have to run for the rest of the round. Go and question Prod. Control5. Equipment failure – call maintenance and tell them you need a 1/4” lock washer. Wait till received.6. Go and ask the Plant manager how the current round of wage bargaining is going.

Notes1. Prepare the orders in the sequence they are received.

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E CO2 H2O

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

Fusers’ work instructionsRound 3

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AREA Fusing STD # 2035 STANDARD WORK GUIDE Job Title Approved by Revision Date Fuser J Lee Round 3 14/9/08 Time #

Wo

rk

Wa

lk

Process description Key points Visual aides

1 Determine next product to bui ld based on replenishment of product taken from WIP storage.

Coordinate production with the other fuser so as not overproduce – max 2.

2 Pick up the relevant product template and insert a blank circuit board.

Slide the circuit board to the top right corner of the template and line up the holes with the grid.

3 Place template on the table, pick up the nano dot dispenser matching the colour of the templante and fuse the nano dots to the circuit board through the holes in the template.

Hold the nano dot dispenser close to the template and use thumb to draw out the nano dot. Be careful to place the dots inside the grid.

4 When all dots are applied, remove circuit board from template and place the completed product in the appropriate WIP storage location.

Check template to ensure no dots are on the lines.

1. Critical 2. Safety 2. Look

Fusers’ work instructionsRound 4

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AREA Fusing STD # 2035 STANDARD WORK GUIDE Job Title Approved by Revision Date Fuser J Lee Round 4 14/9/08 Time #

Wo

rk

Wa

lk


1 Determine next product to bui ld based on replenishment of product taken from FG storage.

Coordinate production with the Laser Cutter so as not overproduce – maximum of 2 per product.

2 Pick up the relevant nano dot dispenser and fuse a nano dot to the circuit board strip being held by the Laser Cutter.

Use a thumb to draw out the nano dot. Be careful to place the dots inside the grid.


LaserCutters

Laser Cutters’ work instructionsRound 1Purpose• To laser cut out the individual squares.

Materials• Circuit boards with nano dots• Laser scissors• 2 black changeover timers• 2 downtime dice

Procedures1. The circuit boards with nano dots required for each order are delivered by the material handlers.2. Cut the circuit boards into individual squares.3. When the order is complete, notify the material handler to collect the order.4. When changing between different products, turn over the black changeover timer, wait for the changeover to take

place (when the sand runs out), then proceed with production.5. When every 5th order is received, before starting production, roll the downtime dice and take the action below

depending on what number is rolled:1. Equipment failure – call maintenance and tell them you need a 1/4” X 3/4” nut & bolt. Wait till received.2. You are concerned about running out of parts in the warehouse. Go and question the store person.3. Equipment failure – call maintenance and tell them you need a 3/16” X 3/4” nut & bolt. Wait till received.4. You are concerned about what you will have to run for the rest of the round. Go and question Prod. Control5. Equipment failure – call maintenance and tell them you need a 1/4” flat washer. Wait till received.6. Go and ask the Plant manager how the current round of wage bargaining is going.

Notes1. Be careful – the laser scissors are sharp!2. Prepare the orders in the sequence they are received.

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Laser Cutters’ work instructionsRound 3

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AREA Laser Cutting STD # 2035 STANDARD WORK GUIDE Job Title Approved by Revision Date Laser Cutter J Lee Round 3 14/9/08 Time #

Wo

rk

Wa

lk



Coordinate production with the other Laser Cutter so as not overproduce – maximum of 60 per product.

2 Pick up the circuit board from the WIP storage location and cut the board into strips along the longest side.

Cut the strips into 2 piles with same pattern of the nano dots. Be careful while cutting – the Lasers are sharp.

3 Turn one pile of strips 180º and pick up both piles stacking them on top.

This will result in all strips having the nano dots in the same pattern.

4 Cut the squares into two piles – blank squares in the waste pile and the nano dot squares onto an empty space on the FG storage location.

Make sure the stack is lined up to cut. There will be 5 nano dot squares per storage location.


Laser Cutters’ work instructionsRound 4

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AREA Laser Cutting STD # 2035 STANDARD WORK GUIDE Job Title Approved by Revision Date Laser Cutter J Lee Round 4 14/9/08 Time #

Wo

rk

Wa

lk



Coordinate production with the other Laser Cutter so as not overproduce – maximum of 2 per product.

2 Pick up the circuit board from the WIP storage location and hold it for the fuser to apply a nano dot.

3 Cut the nano dot squares onto an empty space on the FG storage location.

Be careful while cutting – the Lasers are sharp.


Sorters

Sorters’ work instructionsRound 1Purpose• To sort the final product from the waste material.• To inspect the final product to ensure it is good quality.

Materials• Nano dot squares and blank squares.

Procedures1. The nano dot squares and blank squares for each order are delivered by the material handlers.2. Sort the squares into two piles – ones with nano dots and blanks.3. Discard the blanks.4. Inspect the ones with nano dots to ensure good quality.5. When the order is complete, notify the material handler to collect the order.

Notes1. Prepare the orders in the sequence they are received.

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Sorters’ work instructionsRound 3

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MaterialHandlers

Material handlers’ work instructions 1Round 1Purpose• To move material through the factory

Procedures1. Transport materials (steps 2 – 6) as directed by staff.2. Collect orders from production control and deliver to the warehouse.3. Collect circuit boards and nano dots from the warehouse and deliver to the Fusing workstation.4. Collect circuit boards with nano dots from the Fusing workstation to the Laser Cutting workstation.5. Collect the cut squares from the Laser Cutting workstation to the Sorting workstation.6. Collect the finished nano dot squares from the Sorting Station to the Shipping location.

Notes1. Only material handlers are to move material through the factory.2. Priorities are set by who screams the loudest.

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Material handlers’ work instructions 2Round 1Purpose• To move material through the factory

Procedures1. Transport materials (steps 2 – 6) as directed by staff.2. Collect orders from production control and deliver to the warehouse.3. Collect circuit boards and nano dots from the warehouse and deliver to the Fusing workstation.4. Collect circuit boards with nano dots from the Fusing workstation to the Laser Cutting workstation.5. Collect the cut squares from the Laser Cutting workstation to the Sorting workstation.6. Collect the finished nano dot squares from the Sorting Station to the Shipping location.

Notes1. Only material handlers are to move material through the factory.2. Priorities are set by who screams the loudest.

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Material handlers’ work instructionsRound 3 & 4

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Purpose• To ensure that the Fusers do not run out of raw material.

Procedures• Work with the warehouse to replenish the point of use storage at the Fusing workstation.

Shipping

Shipping work instructionsRound 1Purpose• To ship finished goods to the customer.

Procedures1. Receive the finished products delivered by the material handler.2. Check the finished products against the customer order to ensure that the product type, quantity and

quality are correct.3. Notify Production control of any discrepancies in quantity or product type.4. Notify Quality of any quality issues.5. Once the order is correct, ship the product to the customer.

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Procedures1. When the customer announces the order, deliver the product by sweeping the correct quantity from

the finished product storage locations.2. After each delivery, move any remaining products forward to maintain FIFO.

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Maintenance

Maintenance log sheetRound No. ______

No. Dept Part required

Total downtime

(min)

Comments

1

2

3

4

5

6

7

8

9

10

11

12

13

Maintenance work instructionsRound 1Purpose• To fix equipment when problems occur.

Materials• Maintenance tool box.• A caliper to measure the bolts.• 2 stopwatchs to measure downtime.• Maintenance log sheet.

Procedures1. Stay in the maintenance workshop unless you receive a call from an operators when equipment is

broken down.2. When called to a breakdown, start the stopwatch and time total downtime (stop when the problem is

fixed).3. Find out from the operator what part is required to fix the equipment.4. Return to the maintenance workshop and search through the tool box to find the part.5. Measure the part to verify it is correct.6. Return to the equipment and fix the equipment (refer note 2).7. Record the details on the Maintenance log sheet

Notes1. A 1/8” X 3/4” nut & bolt refers to the thread on the bolt that is 1/8” in diameter and 3/4” in length.2. For this simulation, the equipment will be considered “fixed” when you show the operator the correct

part.

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Maintenance work instructionsRound 3

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Purpose• Maintain equipment through a Preventative Maintenance program and react quickly to fix failures.

Materials• Maintenance tool box 5S.• 2 stopwatchs to measure downtime.• Maintenance log sheet.

Procedures1. You have applied 5S to you toolbox and made it mobile so you can take this to the operations rather

than it being kept in the maintenance workshop.2. Use stopwatch to time downtime (same as round 1).3. Record the details on the Maintenance log sheet

Maintenance work instructionsRound 4

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Purpose• Develop operators to perform condition monitoring and minor PMs. Perform regular major PMs and

quickly react to fix breakdowns. Constant analysis of data to improve PM system.

Materials• Maintenance tool box 5S.• 2 stopwatchs to measure downtime.• Maintenance log sheet.

Procedures1. Congratulations – the improvements to the PM system and condition monitoring have resulted in

equipment failures being a rarity.2. Record any downtime on the Maintenance log sheet.

Quality

Quality work instructionsRound 1Purpose• As the Quality person, you job is to fix quality problems.

Materials• Quality log sheet

Procedures1. During the round, monitor quality and address any customer concerns.2. Record problems on the Quality log sheet.

Notes1. Make any quality problems an “emotional” event.

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Quality work instructionsRound 3 & 4

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Purpose• As the Quality person, you have been working with production to proactively improve quality rather

than the continual fire fighting in previous rounds.

Materials• Quality log sheet• Visual quality standards• Error proofing templates for Fusing

ProceduresSet up• You have worked with the customer to develop visual quality standards.• Work with operators to make sure they are aware of the quality standards and are posted in the work

areas.• You have developed error proofing templates to prevent incorrect placement of nano dots at the

Fusing operation. Work with the Fusing team to make sure they are able to use the templates correctly.

During the round• Monitor quality issues and work with the production team to resolve.• Record problems on the Quality log sheet.

Quality log sheet Round No. ______

No. Dept Product Qty Comments

1

2

3

4

5

6

7

8

9

10

11

12

13

E – example quality product after Fusing operation

Nano dotplaced incentre

Nano dottouchinga line

CO2 – example quality product after Fusing operation



H2O – example quality product after Fusing operation



Quality board – finished product

Acceptable quality = no visible damage to the nano dot

Note: condition of the backing does not affect product quality

Cut Folded Scratched

ContinuousImprovement

CI observation sheet Round No. ______

No. Operation Observation Type of waste

Time (sec)

1

2

3

4

5

6

7

8

9

10

11

12

13

CI work instructionsRound 1Purpose• As the Continuous Improvement coordinator, you job is to identify and implement process

improvements.

Materials• CI observation sheet

Procedures1. Use the CI observation sheet to document any problems you see during the round and any ideas for

improvement.2. At the end of the round, you will be asked for your observations and ideas.

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CI work instructionsRound 3 & 4

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Purpose• As the Continuous Improvement coordinator, you job is to develop the expertise of your people in

process improvement.

Materials• CI observation sheet

Procedures• You have worked with the production cells through kaizen events which have achieved many

improvements. These improvements have been incorporated in the Standard Work.• Use the CI observation sheet to document any problems you see during the round and any ideas for

improvement.• At the end of the round, you will be asked for your observations and ideas.

PlantManager

Plant manager work instructionsRound 1Purpose• As Plant Manager, the buck stops with you!

Procedures1. Prior to the commencement of the round, you give the troops a motivational speech. 2. The theme of the speech is that we have spent a lot of money on the plant, we have a great process

which is well documented in the work instructions (developed by our fine engineers), and that we better make some money otherwise all our jobs will be on the line.

3. During the round, look for trouble spots and give directions.

Notes• Play the “command & control” plant manager.

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Plant manager work instructionsRound 3 & 4

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Purpose• As Plant Manager, your job is to develop your people and provide leadership.

Procedures• Prior to the commencement of the round, you give the troops a motivational speech. • The theme of the speech is different from round 1. Focus on giving credit to the various teams that

have improved the operations and encouragement & incentive to meet customer requirements.• During the round, give encouragement to your team.

the lean experience factory simulation - materials

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