the lego lean game - dtsato lego lean game author: danilo sato created date: 6/7/2009 12:40:18 am...

The Lego Lean Game

Danilo Sato, Francisco Trindade

XP 2009 – Sardinia - Italy

25th May 2009

© ThoughtWorks 2008

•! Quick introduction

•! Simulating a production line

•! How about software?

Agenda


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•! Lean concepts starting to be noticed in the software world

•! But not everyone has had contact with Lean principles and practices

We’re here to introduce you to Lean

Hands On!

Why are we here?


•! Toyota Production System

–! Revolutionized manufacturing (Ford vs. Toyota)

–! Started to be applied to different areas

•! Google, Dell, Zara, …

•! Product Development

•! Supply Chain Management

•! Software

•! Healthcare

•! …

Lean?


Lean?


•! Push and Pull Systems

•! Kanban

•! Systems Thinking

•! Flow

•! Heijunka

•! Yatai (Work Cell)

•! And more…

What we want to show


•! Let’s simulate a production line…

Hands On – 1st Step


•! 4 Teams •! 4 rounds of 40 seconds

•! Follow the instructions •! Build houses •! 1 Piece = $ 1.00 •! 1 House = $ 25.00

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Stay Motivated!


What went wrong?

Houston we have a problem…


•! Visible Inventory

•! Over/Under Production

Waste


•! Overproduction

•! Waiting

•! Unnecessary Transportation

•! Overprocessing

•! Inventory

•! Motion

•! Defects

7 Wastes of Manufacturing


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Push and Pull Systems


•! Push System – upstream information

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Push and Pull Systems


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•! Push System – upstream information

•! Pull System – downstream information

•! Physical device

•! Signals demand to downstream processes

•! Regulates demand on a pull system

•! Limits Work in Process (WIP)

•! Aids visual control

•! Self-directing

Kanban


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Kanban


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Kanban

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Kanban


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Kanban


•! Using Pull and Kanban

–! Setup minimum buffers at intermediate steps

–! Demand comes first

–! Items are produced to fill gaps in the buffers

•! 4 rounds of 40 seconds

Hands On – 2nd Step


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Stay Motivated!


What went wrong?



•! Another type of waste

•! Some people working more than others

•! Mura (Unevenness)

•! Heijunka

Unleveled Process


•! Final goal is a leveled process

•! Production line must be a continuous flow

•! One piece is bought when one piece is delivered

•! Sustainable pace

Flow


•! Why does it still feel wrong?

•! What are the other teams doing?

•! What’s the purpose of the system?

Systems Thinking


•! Do we need 4 teams to build a house?

•! Teams 1 and 2 have overlapping tasks

Let’s Experiment


•! Multi-skilled worker

•! Single piece flow

Yatai (Work Cell)


•! Using Work Cells

–! Each person builds a house

–! Round of 160 seconds

–! Signal (raise your hand) if you finish your house

Hands On – 3rd Step


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Stay Motivated!


What went wrong?



•! Continuous Improvement

•! Reflect and adapt

•! Learn by standardizing

•! Long term thinking

•! Respect People

Kaizen


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Improving the Process


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Hands On – 4th Step


•! Discuss your own process

•! 1 round for each team

Stay Motivated!


Our Results


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•! We saw some of the practices

•! Practices are contextual

•! Underlying principles must be understood

–! Like agile!

Is That All?


What is Lean?


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•! Manufacturing is not the same as Software Development

•! Lean Product Development

–! Knowledge flow is not the same as material flow

Lean 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)

•! Example: Push System in Software



•! Example: Pull System in Software



Kanban


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•! Much more:

–! Eliminate Waste

–! Create Knowledge

–! Build Quality In

–! Defer Commitment

–! Deliver Fast

–! Respect People

–! Improve System



•! Lean:

–! Genchi Gembutsu

–! A3

–! 5 Whys?

–! Stop the Line

–! Andon

–! Jidoka

–! Mistake Proofing

Thank you!

Questions?

[email protected]

[email protected]


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the lego lean game - dtsato lego lean game author: danilo sato created date: 6/7/2009 12:40:18 am...

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