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Par$cipa$ve

Games For Learning Lean


Copyright PICSIE Books, 2010 These slides may be copied for use by the Purchaser of the book to play the games, but may not otherwise be copied or distributed.

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Airplane Games

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Opera$on 1: Fold 1

A4 sheet

Fold in half
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Fold down corners


3

Opera$on 2: Fold 2

Make second Fold


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Opera$on 3: Fold 3

Turn sheet Thru 90 degrees. Fold in half along Centre fold

Fold the wings over the body on both sides. Note 1 cm. 1 cm. Top (sheet) View Side Views
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Opera$on 4: Fold 4

Fold up both Wing $ps.

Side View
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Top View (when opened)


6

Opera$on 5: Fold 5
A A
Grasp plane here between thumb and forenger of leY hand

Before

AYer

End Views (Sec$on A-A)

At right hand end of plane, Insert thumb and and middle nger, between ver$ces of M

then push up central por$on with index nger to form the tail..

A Side View
and a]en all folds
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A Final Side View


7

Opera$on 6
Side Views

With red pen, add circular decal to LeY side of plane

and with Blue pen, add circular decal to Right side of plane
8

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Opera$on 7

Top View

Side Views

End Views

Open up wings, and straighten all edges


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Quality Check (for A4 size paper)


Tail must be at least 2 cm above wing

100mm +/- 5mm

Side View

Folds on wings Aligned within 3 mm

Tail must be at least 2 cm above wing

End View
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98 mm +/- 5mm

Top View
10

JIT Game Layout


Op 1 Op 6 Op 5 Op 4 Op 3 Op 2

Op 7 Customer Dispatch Op 8
11

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Customer Requirements
The rst delivery is due aYer 3 minutes At 2 minutes, and each minute thereaYer, the Customer rolls two dice. The rst Dice roll indicates how many planes will be required in the next minute The second Dice roll indicates the decal colours:
Roll 1 or 2: Decal colours: Red and Red Roll 3 or 4: Decal colours Red and Blue (B on top right) Roll 5 or 6: Decal colours Blue and Blue

In other words, there is a 60 second order lead $me. Backorders (i.e. late) not allowed. Stop aYer 12 minutes. (i.e. 10 deliveries)
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Dispatch Player Tasks


You need to supply the Customer with his or her requirements. Keep a record of all orders received. Please keep a record of all orders that you are NOT able to meet. Record the number of airplanes not met. Part orders are acceptable. Late orders are NOT acceptable.
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Record Sheet: Round 1


Minute 1 2 3 4 5 6 7 8 9 10 11 12 0 Note: If Closing inventory is less than opening inventory, the dierence must be added to the number of airplanes NOT delivered. This is for con$nuity reasons. Note: Late orders are NOT accepted.
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Orders Recd 0

Orders Met 0 0

Round Results No of players No NOT delivered Closing WIP & FGI Opening WIP & FGI Inventory buildup

Record Sheet: Round 2


Minute 1 2 3 4 5 6 7 8 9 10 11 12 0 Note: If Closing inventory is less than opening inventory, the dierence must be added to the number of airplanes NOT delivered. This is for con$nuity reasons. Note: Late orders are NOT accepted.
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Orders Recd 0

Orders Met 0 0

Round Results No of players No NOT delivered Closing WIP & FGI Opening WIP & FGI Inventory buildup

Record Sheet: Round 3


Minute 1 2 3 4 5 6 7 8 9 10 11 12 0 Note: If Closing inventory is less than opening inventory, the dierence must be added to the number of airplanes NOT delivered. This is for con$nuity reasons. Note: Late orders are NOT accepted.
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Orders Recd 0

Orders Met 0 0

Round Results No of players No NOT delivered Closing WIP & FGI Opening WIP & FGI Inventory buildup

Wing Decal Pain$ng


Customer demand is known to be in the ra$o of
One with two red decals One with red and blue decals One with two blue decals

Therefore, for each batch of 6 airplanes you receive from the previous worksta$on, you should paint two of each type given above.
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Airplane Lean Game Measures


Number of airplanes NOT delivered Total WIP and nished goods at end of game. Number of rejects due to quality reasons Number of players Note: Final (ending) inventory must be at least as much as ini$al (beginning) inventory, in order to assure con$nuity. Inventory here means WIP and nished goods. If ending inventory is less than star$ng inventory, the number will be deducted from total airplanes delivered.
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Quality Checks
Your task is to do Quality spot checks, according to the specica$on You work for the Paper Airplane company, but have responsibili$es for airplane safety to the CAA (Cardboard AircraY Authority) So, you should not pass on defec$ve airplanes. You do not need to measure every plane . Measure a few planes but visual checks are OK. If an airplane is defec$ve it must be scrapped. No rework.
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Player Instruc$ons Round 1


Collect the raw material or partly built up airplanes from the previous opera$on in batches of 6 Undertake your required step. (Use the Airplane build instruc$ons.) Place the part-made or complete airplanes in the outbound work in process area.

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20

Improvement Ac$vity
Iden$fy and remove waste Map the process Implement your changes You may change anything, except the basic airplane design. The Customer requirement mix will not change and cannot be changed. You should start again with zero inventory. Your instructor will indicate how much $me you have to make and implement changes.
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JIT Lean Game: Possible Changes


Layout One piece ow Pull: Kanban / DBR / CONWIP Postponement Successive and own quality checks Takt $me (prac$cal) 60/3.5 = 17.1 seconds. Say 15 seconds. Line (ac$vity) balance Realloca$on of resources. Visual management Problem solving Pokayoke (?)
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Layout Types Game


In 12 minutes, build and inspect airplanes according to each of the following types: Everyone builds and inspects the complete airplane individually Two teams: rst team builds half the airplane individually (in parallel); second team builds the second half individually. WIP area between. Two parallel assembly lines, with job specializa$on. In a U shape cell with X working? One long assembly line, with job specializa$on.
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Cell Layout Types Airplane Game


Table of Considera$ons
Types > Considera$ons V Produc$vity Training Inventory Visibility Traceability Boredom Quality Tooling Supervision
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Short-cycle Assembly Line Tradi$onal and CONWIP

Individuals do Two parallel Two groups. the whole task lines, each with Each player greater work makes half. WIP content in between groups.

Cell Layout Types Airplane Game


The Four Types
Op1to 8 Op1to8 Op1to8 Op1to8 Op1to8 Op1to8 Op1to8 Op1to8
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Individual Op1 Line Op2 And CONWIP Op3 Op4 Op5 Op6 Op7 Op8

Parallel Op1,2 Op3,4 Op5,6 Op7,8 Op1,2 Op3,4 Op5,6 Op7,8 Transverse Op1to4 Op1to4 Op1to4 Op1to4 Op5to8 Op5to8 Op5to8 Op5to8

WIP

25

Squares Games

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26

B A

D
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B A D

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28

B
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B
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31

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32

C D
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C D
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D A E
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35

D A

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36

C
(Cut Out) A

B
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(Cut Out) A

B
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A B

C Exclude This piece E D E


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C B Exclude This piece D E


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40

E A D C B E
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E B D C D E
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42

Changeover Instruc$ons
Assemble into an outer rectangle. And an inner rectangle The inner rectangle is mage up of various pieces The circle requires hea$ng for 20 seconds before inser$on in the hole. Once heated, it can only be handled with two pens / pencils The arrow on the circle must be aligned with a line drawn from bo]om leY corner of inner rectangle to top right corner of inner rectangle. During changeover reduc$on, s$cky tape or staples may not be used.
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Prepara$on
Cut out pieces and place in an envelope. Paper is OK, but cardboard is be]er The circle must be placed in another envelope, located (say) 5m away from the rst envelope. The diagonal line, for alignment with the arrow, must not be drawn on the sheet. The heater for the circle is shown on a separate sheet.
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Heater
HOT

Place the circle in this heater for 20 seconds prior to installa$on. Handle the circle with two pencils, when hot. Align the arrow with the diagonal, drawn corner to corner. The Circle will remain at an acceptable temperature for 20 seconds aYer hea$ng. The Heater Square containing the circle may not be moved once heat treatment has begun.
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Dice Games

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46

Cut and Fill Games

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47

Cut and Fill Game


Ini$al Round (Push System) Line Balancing Kanban CONWIP Self Balancing Discussion

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48

Cut and Fill: Flow Diagram

1 Cut out batch

square

Ini$al player Alloca$on: One per Sta$on, plus a Material Handler, and an Industrial Engineer
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Cut and Fill: Player Card


1. Read schedule. Cut out batch. 2. Draw shape. 3. Write number inside. 4. Colour Red or Blue
** 10 second change between colours **

Product Number 3 4 5 6 7 8

THREE

FOUR

FIVE

SIX
Blue

SEVEN

EIGHT EIGHT
Blue

Red Red

Red

Blue

5. Colour Green 6. Cut out shapes 7. Glue extra piece on back 8. Inspect

Green

Green

Green

THREE

FOUR

FIVE

SIX

SEVEN

EIGHT EIGHT EIGHT EIGHT

THREE

FOUR

FIVE

SIX

SEVEN

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50

Cut and Fill Game: Player Instruc$ons


Sta$on 1: Read the schedule. Cut out the required batch of products. Do not cut out individual products. Sta$on 2: Draw the shapes on each square. Sta$on 3: Write (PRINT) the appropriate product number inside each square. Use words not numbers. Sta$on 4: Colour in red or green as shown. If (when) you change colours you must $me 10 seconds. Sta$on 5: Colour in Green as shown. Sta$on 6: Cut out the shapes. Sta$on 7: S$ck the shape on a blank square. Sta$on 8: Inspect: See that colours are correct and that shapes are properly coloured in. Use your judgement.
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Cut and Fill Game: Materials


Sta$on 1: Scissors. Sta$on 2: Black felt pen Sta$on 3: Black felt pen Sta$on 4: Red and Blue felt pens. Timer Sta$on 5: Green felt pen Sta$on 6: Scissors Sta$on 7: Glue S$ck and Scissors Sta$on 8: nil All sta$ons need a copy of the Player Card. Note: Select fairly thick felt pens; thin pens slow down the rate of work.
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Cut and Fill Squares


(instructor to cut into fours)

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53

Cut and Fill Game: Customer Order Sequence


Order No Product no Quan$ty 1 2 3 4 5 6 7 8 9 10 11 12 4 3 7 5 6 4 7 8 3 8 5 4 4 2 3 1 4 3 2 1 4 3 2 3 Order No Product No Quan$ty 13 14 15 16 17 18 19 20 21 22 23 24 5 4 6 7 3 4 7 6 5 3 7 4 2 5 3 1 2 3 3 2 1 3 2 2
54

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Cut and Fill: Balance Table


Opera$on 1 2 3 4 5 6 7 8 Ac$vity Time Adjusted Time Grouping

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55

Operator Balance Board

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56

Kanban Square
One of these is required between each pair of Operators

The Square may contain only one Product. When the square is occupied the previous opera$on must stop work. When the square is empty the previous opera$on is authorised to begin work to ll the square.
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FIFO Lane
One of these is required between Complex Stages and where there is Changeover

The FIFO lane may contain only three Products. Products must move up the line from leY to right When the leYmost square is occupied the previous opera$on must stop work. When the leYmost square is empty the previous opera$on is authorised to begin work to ll the square.
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Cut and Fill Game: Measures


Round Basic Balanced Line Kanban CONWIP Bucket Brigade Completed WIP Rejects Lead $me Players Produc$vity

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59

Cut and Fill: Balanced (?)


square

6 2 3 4 5 6

7 8 7

1 Cut out batch

square

Notes: 2 and 3 done by 1 operator; 6 and 7 each done by 2 operators Can operators 7 also do inspec$on?
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5S Numbers Game

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61

49 17 81 33

65

53 85
69

5
37

41

73 89

21
54

57

9
42

29

45

61 93 13 77
14 94
46

86

18
34

2 66

38

26
10
43

74

51 50
11
68

70
39

58
75

78

62
47

67
35

71

63

83
36

55 91
40

59
76

31

95
79

15

52 84

88 56

72

60

24

12

92

16
44 48

80
62

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Sheet 1

49
33

17

53

41

21
54

37

57

25
42

29
13 14

45

61

18
34

38

51 50
11
36 39

22
55

26
10
43

30
46

58

62
47

19
35

7
40

23
8

27 28

63 59

31
16

15

52

60

20

56

24

12

64
48

32
63

44

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Sheet 2

49
33

17

53

41

21
54

37

57

25
42

29
13 14

45

61

18
34

38

51 50
11
36 39

22
55

26
10
43

30
46

58

62
47

19
35

7
40

23
8

27 28

63 59

31
16

15

52

60

20

56

24

12

64
48

32
64

44

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Sheet 3

1 9

2 10

11 3

4 12

5 13

6
14

7 15

8 16

17 18 19 25 26 27
33 41 34 42 35 43

20 28
36 44

21 22 29 30
38 45 46

23 24 31 32
39 47 40 48

49 57

51 58

50 59

52

53

60 61

54 62

55 63

56 64
65

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Sheet 4

49 17 81 33

65

53 85
69

5
37

41

73 89

21
54

57

9
42

29

45

61 93 13 77
14 94
46

86

18
34

2 66

38

26
10
43

74

51 50
11
68

70
39

58
75

78

62
47

67
35

71

63

83
36

55 91
40

59
76

31

95
79

15

52 84

88 56

72

60

24

12

92

16
44 48

80

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66 Sheet 1: Instructor only

49
33

17

53

41

21
54

37

57

25
42

29
13 14

45

61

18
34

38

51 50
11
36 39

22
55

26
10
43

30
46

58

62
47

19
35

7
40

23
8

27 28

63 59

31
16

15

52

60

20

56

24

12

64
48

32

44

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67 Sheet 2: Instructor only

Notes on 5S Numbers Sheets


No missing numbers, except in nal slide 50 and 51 interchanged 3 and 11 interchanged Font of 19 smaller Font of 6 bigger.

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68

Advantages of 5S
Produc$vity (Speed) Reduced varia$on Problem iden$ca$on

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69

The Manufacturing Cell

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70

Manufacturing Cell: Ini$al Layout


Inbound material Welder Outbound material

Raw Material S$llage (situated 30m away) De- burr Scale: 1m


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Finished Goods (FGI) area

Bush Contr.

Assembly

71

Manufacturing Cell Ac$vi$es


Activity A B C D E F G H I J K L M N P Q R S T U V W X Y Z A1 Description Time 120 5 2 3 2 2 5 2 3 3 2 6 2 18 15 2 6 3 4 12 2 200 2 3 10 3

Fetch inbound material from raw material stillage (every 30th cycle) Walk to inbound raw material container Pick up raw material Walk to left side of weld machine Place raw material on left of weld machine Walk to centre of weld machine Remove welded part from jig on weld machine Place welded part in outbound area Walk to left side of weld machine Pick up raw material from left side of weld machine Move raw material to centre of weld machine Secure raw material into jig Start welder Welder runs through cycle Wait for part to cool Pick up welded part and jig from weld machine Visual inspection of part Carry part to bush area (3 out of 4 parts on average) Carry part to de-burr area (every 4th part on average) De-burr (every 4th part on average) Carry de-burred part to bush area (every 4th part) Fetch bushes container (every 200 cycles approx) Pick up bush Walk to assembly table Assemble product Place assembled product in Iinished goods (FGI) area

The demand from a process is 800 products per day. The area works an 8 hour day, with a lunch break of 30 minutes, two 20 minute refreshment breaks, and an addi$onal 10 minutes allowed for comfort.

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72

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73

The Paperwork (Oce) Cell

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74

Dispatch (out)

Counter

Picklist tray.

The Oce
Filing cabinet
Computer

Completed paperwork

le

Printers
For stamp.

1 metre

Note: The Warehouse is North of this area


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In

Basic Cell Analysis Tools


Takt $me One piece ow Value Add and Non Value Add ac$vi$es Work Balance Board Spaghey Diagram. Standard Work Combina$on table. Standard Opera$ng Procedure.

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76

The Paperwork Cell


The Paperwork Cell is the last stage before nal dispatch in a sta$onery company that takes orders over the phone and internet, picks the orders, and ships overnight. Orders are received throughout the day. Average demand is around 760 orders per day, but is expected to rise by around 100 per day. The oce works an 8 hour day with one 30 minute break and two 10- minute breaks. The following is a process ac$vity map collected from video sequences. The $mes are median $mes in seconds for processing a single order. Assume that the workload is evenly distributed throughout the day. (This is unrealis$c, so you should build in an allowance for varia$on).

What you need to do:


What is allowed and what is not

Calculate takt $me (based on an$cipated gures) Calculate the required number of oce workers for one piece ow Go through the list of ac$vi$es and iden$fy the value adding steps Decide on an appropriate target number of oce workers Examine the ac$vi$es and layout cri$cally, and make improvements. Show the new layout on a Layout Diagram Show the revised way of working on a Work Balance Board Anything can be changed or rearranged, but No equipment can be placed on the counter for security and safety reasons A paper invoice is s$ll required

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77

Ac$vity List
Activity No A B C D E F G H I J K L M N O P Q R S T Unit Time (secs) 3 2 3 3 1 3 2 8 15 24 8 3 15 3 6 4 2 2 8 15 Activity Walk to picklist box on counter Pick up picklist Reorient and sort picklist Walk to desk Place picklist in in-basket Walk to computer chair and sit down Pick up picklist from in-basket Scan picklist bar code and wait for order to be retrieved on computer screen Check picklist against original order. All items picked ? (Y/N : if Y (80%) go to activity L N: Enter changes to invoice on computer (20%). Enter reason code for shortage into computer Check paper, insert envelope and start printer Print out 2 copies of the invoice, and an envelope Separate office and customer copies of the invoice Stamp checked , date and clerk number on customer copy Place customer copy of invoice into envelope Place envelope into customer invoice tray Place office copy into file tray (Every approx 10 envelopes) Walk from customer tray to dispatch box, walk back (Every approx 10 copies) Take office copy to filing cabinet and file, walk back

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78

Takt Time
The average rate that work should come out of a cell or line Available $me / demand In an oce this gives an idea of the rate of work Useful for work alloca$on and for calcula$ng the number of workers In an oce, takt is a guideline. No-one expects that workers to complete an order every takt cycle, but over a few hours the takt will approximate the rate In an oce, you should make allowance for demand varia$on and work varia$on - perhaps balance to 80% of takt (90%+ in a factory).

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79

Value adding and waste


Strictly, a value adding ac$vity is something that a customer is prepared to pay for. If it does not add value it is waste In an oce, value add is something that managers or customers would be prepared to pay a third-party provider to do, were this service available. In some oces and service situa$ons it may be good enough to dene waste as anything that prevents a job being done immediately and right rst $me. All waste ac$vi$es should be eliminated or reduced Put all waste ac$vi$es under the microscope. Ques$on them!

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80

One-Piece Flow
Moving pieces between stages one at a $me rather than in batches Batches may appear to be ecient, but penal$es are paid in
Comple$on Time (Lead $me) Space Quality (where a defect is no$ced, and rework is required)

One piece ow has more walk and setup $me, so these must be a]acked.
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Work Balance Board


A board, displayed at the workplace that helps allocate work elements between operators Mark in the takt $me Mark in the target balance cycle Accumulate $mes for each operator Colour waste ac$vi$es dierently
Op1 Op2

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83

Dispatch (out)

Counter

Picklist tray.


Filing cabinet

Spaghey
Computer

Completed paperwork

le

Printers
For sign.

1 metre

Note: The M ovements above are for illustra$on only From Bicheno : Lean Games Book. Please
do not distribute.

In

84

TV News Game

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85

Cross Func$onal Team Exercise: The Daily News


You are a TV news produc$on company. You have 1 hour to make a 5 minute news report to cover two key stories from last week There are 5 departments The Original
Editorial Research Wri$ng Produc$on News Readers

game was developed by Kate Mackle of Thinkow

No internet, printers, copiers. Laptop computers are allowed.


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The News Game (2)


The stories must be
Real Topical Balance not biased Factual Contain at least 3 quan$ta$ve facts interes$ng

There are two news readers


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The News Game (3) Editorial


You choose the stories You tell Research what to research You do not have any input with any other department Once you have decided on the stories you will then and only then communicate with the Research team once only! Editors may discuss Produc$on requirements with the Produc$on sec$on. Editors may monitor progress but may not discuss progress with individual sec$ons or sta.
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The News Game (4) Research


You work with the Editors The Editors tell you what they want to cover in the news reports You research the stories and pass on the research and the editorial instruc$ons to the Wri$ng team You only communicate with the Editors once - when you receive instruc$ons You only communicate with the writers once - when you are ready to hand over your research You do not communicate with any other team.
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The News Game (5) Wri$ng


You have to write up the stories from the informa$on you receive from the Research team. The stories will be read by the News Readers. You only communicate with the Research team once - when you receive your informa$on When you have wri]en up the stories you pass then onto the Produc$on team You only communicate with the Produc$on team once You do not communicate with any other team.
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The News Game (6) Produc$on


Your task is to set up the room so that that everyone can watch the news reports being presented. You must explain to the Reading team how and when and where the stories are to be presented. You receive the stories from the Wri$ng Team and pass them on to the Reading Team. Some text edi$ng is allowed. You only communicate with each of these teams once You do not communicate with any other team. The newscast will begin in EXACTLY one hour.
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The News Game (7) News Reading Team


You must read out the news stories you receive from the Produc$on Team You only communicate with the Produc$on Team once You do not communicate with any other team. When you are ready to present you must sit at the news desks and announce that you are ready You will then present your news reports to the group. Your newscast will take exactly 5 minutes.
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The News Game (8)


Was this Lean? What about Cost, Quality, Delivery, Time? What about value adding? What about communica$on? Who was the customer Who was the nal customer What about specica$on?

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93

The News Game (9): Second Round


The Team (Crew) will now have 15 minutes to decide on how to reorganise for a second 5 minute newscast. The Editors and News readers remain. Other func$ons remain, but may be reorganised. The Team will then be given 20 minutes to prepare for a second 5-minute news cast. New stories must be chosen. No communica$on restric$ons. Once again, no internet, printers, copiers. Laptop computers are allowed.
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Features of Toyota Design Prac$ce


Role of Chief Engineer Authority of Func$onal Managers Check Sheets Leveling the work Bookshelving Set Based Design The Obeya (Big) Room
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Features of Goldra]s Cri$cal Chai Chain Project Management


The Cri$cal Chain rather than the Cri$cal Path Time slack at the end, for the whole project, but not for individual ac$vi$es Time buers at convergent paths, to prevent non-cri$cal holding up cri$cal ac$vi$es

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96

Features of Lean Construc$on Project Management


Develop and grow check lists covering every requirement for every ac$vity. Check these o in advance. Not just monitor the cri$cal path.

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97

Job Breakdown Sheet Template


Important Steps Key Points Anything that may 1. Make or break the job 2. Injure the worker 3. Make the work easier. Knacks or Tricks. Reasons (Something that advances the work.) Reasons for the Key points

1. 2. 3. 4.
AYer Patrick Graup and Robert Wrona From Bicheno : Lean Games Book. Please The TWI Workbook, Produc$vity do not distribute.

98

The Happy Pig

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99

Happy Pig

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100

Standards
To standardise a method is to choose out of many methods the best one, and use it. What is the best way to do a thing? It is the sum of all the good ways we have discovered up to the present. It, therefore becomes the standard. Todays standardisa$on is the necessary founda$on on which tomorrows improvement will be based. If you think of standardisa$on as the best we know today, but which is to be improved tomorrow - you get somewhere. But if you think of standards as conning, then progress stops. Henry Ford, Today and Tomorrow, 1926

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101

Be]er Happy Pig?

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102

Even Be]er Happy Pig?

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103

Drawing A Be]er Happy Pig?


Note 3-D tail Note Eyes Oval Oval

Oval

Curve

Note Alignment Of Ovals Note Construc$on From Bicheno : Lean Games Book. Please Lines
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Note Straight

104

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