Abstract: - Production and operation management principles - using LEGO cars - Basic production concepts: 1. Process improvements 2.

Lean manufacturing 3. Cycle time reduction 4. Mass customization 5. Pull production strategies 6. Supplier capacity 7. 5S 8. Jadoka 9. Heijunka 10. Kanban 11. Kaizen. -Activities running in class

Apparatus: LEGO cars: subassemblies 1. Front-end-seat 2. Front-end have three types: four purple(sports model), four green(hybrid model) and 10 white(standard) 3. Tire rim have three types: black, gold, grey(standard)

Exercises: Students split into six groups of three to four. Tier 1: 1. Each group was given a box of LEGO cars. 2. No instructions. 3. Build the car as fast as possible. 4. Each group was given five extra parts that did not belong to the LEGO car. 5. No time limits. 6. Criteria that being assessed: time taken to build each car and the quality of the products. Issues happen in tier 1: 1. Quality of the products. 2. Lack of proper training and instruction. Solution for tier 1: 1. The importance in using 5S principle: sorting, straightening, shining, standardizing, sustaining. 2. Emphasizing on how sorting and straightening can reduce cycle time.

Students were given five minutes for practicing and asking the instructor for tips on improving the assembly process. Tier 2: 1. Students separate into six groups, with three students each group. Each group contains two disassemblers and one quality control worker. 2. Five extra parts given. 3. Students were given five minutes for preparation sorted or rid the bags of excess parts, organized the parts in an effort to improve efficiency and reduce time cycle. 4. Students were given five minutes to build LEGO car as much as possible. LEGO car passed after QC worker inspect and the car was counted.

Discussion in tier 2: 1. Specialization reduced cycle time of production. 2. Jadoka or quality at the source. All departments responsible in maintaining the quality of the product not just the responsibility of QC worker only defect do not get passed on to the nest process. 3. Benefit of having five minutes discussion for preparation. 4. Heijunka - Process of production smoothing or leveling balance workload between the roles. 5. Kanban production scheduling system pull production system reduced work in progress.

Tier 3: 1. The car must be manufactured in four different options: model, tire, headlights, and grille. 2. Students were given five minutes for preparation. 3. Three assemblers, two disassembler, one quality control worker. 4. Task: build 20 cars (made-to-order) as fast as possible with few quality issues as possible. Issues and discussion in tier 3: 1. Supplier capacity issues lean manufacturing. 2. Communication among the group members. 3. Kaizan continuous improvements. 4. Discussion for improvements: reduce number of variables that need to be considered for each build-to-order car.

Tier 4: 1. The cars were built either standard package or with the upgrade package. 2. Students arrange the order in a way that would minimize cycle times.

3. Students could take on any role that would help reduce cycle times principle of heijunka.

Conclusion: 1. Experiential exercise. 2. Each tier introduced some of the management principles.