Professional Documents
Culture Documents
Airplane Games
Opera$on 1: Fold 1
A4 sheet
Fold
in
half
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
Opera$on 2: Fold 2
Opera$on 3: Fold 3
Fold
the
wings
over
the
body
on
both
sides.
Note
1
cm.
1
cm.
Top
(sheet)
View
Side
Views
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
5
Opera$on 4: Fold 4
Side
View
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
Opera$on
5:
Fold
5
A
A
Grasp
plane
here
between
thumb
and
forenger
of
leY
hand
Before
AYer
At right hand end of plane, Insert thumb and and middle nger, between ver$ces of M
then push up central por$on with index nger to form the tail..
A
Side
View
and
a]en
all
folds
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
Opera$on
6
Side
Views
and
with
Blue
pen,
add
circular
decal
to
Right
side
of
plane
8
Opera$on 7
Top View
Side Views
End Views
Side View
End
View
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
98 mm +/- 5mm
Top
View
10
Op
7
Customer
Dispatch
Op
8
11
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
$me.
Backorders
(i.e.
late)
not
allowed.
Stop
aYer
12
minutes.
(i.e.
10
deliveries)
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
12
Orders Recd 0
Orders Met 0 0
Round Results No of players No NOT delivered Closing WIP & FGI Opening WIP & FGI Inventory buildup
Orders Recd 0
Orders Met 0 0
Round Results No of players No NOT delivered Closing WIP & FGI Opening WIP & FGI Inventory buildup
Orders Recd 0
Orders Met 0 0
Round Results No of players No NOT delivered Closing WIP & FGI Opening WIP & FGI Inventory buildup
Therefore,
for
each
batch
of
6
airplanes
you
receive
from
the
previous
worksta$on,
you
should
paint
two
of
each
type
given
above.
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
17
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.
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
19
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
$me
you
have
to
make
and
implement
changes.
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
21
Individuals do Two parallel Two groups. the whole task lines, each with Each player greater work makes half. WIP content in between groups.
Individual Op1 Line Op2 And CONWIP Op3 Op4 Op5 Op6 Op7 Op8
Parallel Op1,2 Op3,4 Op5,6 Op7,8 Op1,2 Op3,4 Op5,6 Op7,8 Transverse Op1to4 Op1to4 Op1to4 Op1to4 Op5to8 Op5to8 Op5to8 Op5to8
WIP
25
Squares Games
26
B A
D
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
27
B A D
28
B
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
29
B
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
30
31
32
C
D
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
33
C
D
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
34
D
A
E
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
35
D A
36
C
(Cut
Out)
A
B
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
37
(Cut Out) A
B
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
38
A B
40
E
A
D
C
B
E
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
41
E
B
D
C
D
E
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
42
Changeover
Instruc$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.
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
43
Prepara$on
Cut
out
pieces
and
place
in
an
envelope.
Paper
is
OK,
but
cardboard
is
be]er
The
circle
must
be
placed
in
another
envelope,
located
(say)
5m
away
from
the
rst
envelope.
The
diagonal
line,
for
alignment
with
the
arrow,
must
not
be
drawn
on
the
sheet.
The
heater
for
the
circle
is
shown
on
a
separate
sheet.
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
44
Heater
HOT
Place
the
circle
in
this
heater
for
20
seconds
prior
to
installa$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$ng.
The
Heater
Square
containing
the
circle
may
not
be
moved
once
heat
treatment
has
begun.
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
45
Dice Games
46
47
48
square
Ini$al
player
Alloca$on:
One
per
Sta$on,
plus
a
Material
Handler,
and
an
Industrial
Engineer
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
49
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
THREE
FOUR
FIVE
SIX
SEVEN
50
53
55
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.
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
57
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.
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
58
59
6 2 3 4 5 6
7 8 7
square
Notes:
2
and
3
done
by
1
operator;
6
and
7
each
done
by
2
operators
Can
operators
7
also
do
inspec$on?
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
60
5S Numbers Game
61
49 17 81 33
65
53
85
69
5
37
41
73 89
21
54
57
9
42
29
45
61
93 13
77
14
94
46
86
18
34
2 66
38
26
10
43
74
51
50
11
68
70
39
58
75
78
62
47
67
35
71
63
83
36
55
91
40
59
76
31
95
79
15
52 84
88 56
72
60
24
12
92
16
44
48
80
62
Sheet 1
49
33
17
53
41
21
54
37
57
25
42
29
13
14
45
61
18
34
38
51
50
11
36
39
22
55
26
10
43
30
46
58
62
47
19
35
7
40
23
8
27 28
63 59
31
16
15
52
60
20
56
24
12
64
48
32
63
44
Sheet 2
49
33
17
53
41
21
54
37
57
25
42
29
13
14
45
61
18
34
38
51
50
11
36
39
22
55
26
10
43
30
46
58
62
47
19
35
7
40
23
8
27 28
63 59
31
16
15
52
60
20
56
24
12
64
48
32
64
44
Sheet 3
1 9
2 10
11 3
4 12
5 13
6
14
7 15
8 16
17 18 19 25 26 27
33
41
34
42
35
43
20 28
36
44
21 22 29 30
38
45
46
23 24 31 32
39
47
40
48
49 57
51 58
50 59
52
53
60 61
54 62
55 63
56
64
65
Sheet 4
49 17 81 33
65
53
85
69
5
37
41
73 89
21
54
57
9
42
29
45
61
93 13
77
14
94
46
86
18
34
2 66
38
26
10
43
74
51
50
11
68
70
39
58
75
78
62
47
67
35
71
63
83
36
55
91
40
59
76
31
95
79
15
52 84
88 56
72
60
24
12
92
16
44
48
80
49
33
17
53
41
21
54
37
57
25
42
29
13
14
45
61
18
34
38
51
50
11
36
39
22
55
26
10
43
30
46
58
62
47
19
35
7
40
23
8
27 28
63 59
31
16
15
52
60
20
56
24
12
64
48
32
44
68
Advantages
of
5S
Produc$vity
(Speed)
Reduced
varia$on
Problem
iden$ca$on
69
70
Bush Contr.
Assembly
71
Fetch inbound material from raw material stillage (every 30th cycle) Walk to inbound raw material container Pick up raw material Walk to left side of weld machine Place raw material on left of weld machine Walk to centre of weld machine Remove welded part from jig on weld machine Place welded part in outbound area Walk to left side of weld machine Pick up raw material from left side of weld machine Move raw material to centre of weld machine Secure raw material into jig Start welder Welder runs through cycle Wait for part to cool Pick up welded part and jig from weld machine Visual inspection of part Carry part to bush area (3 out of 4 parts on average) Carry part to de-burr area (every 4th part on average) De-burr (every 4th part on average) Carry de-burred part to bush area (every 4th part) Fetch bushes container (every 200 cycles approx) Pick up bush Walk to assembly table Assemble product Place assembled product in Iinished goods (FGI) area
The demand from a process is 800 products per day. The area works an 8 hour day, with a lunch break of 30 minutes, two 20 minute refreshment breaks, and an addi$onal 10 minutes allowed for comfort.
72
73
74
Dispatch (out)
Counter
Picklist tray.
The
Oce
Filing
cabinet
Computer
Completed paperwork
le
Printers
For stamp.
1 metre
In
76
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$ll required
77
Ac$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
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).
79
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
$me,
so
these
must
be
a]acked.
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
81
83
Dispatch (out)
Counter
Picklist tray.
Filing
cabinet
Spaghey
Computer
Completed paperwork
le
Printers
For sign.
1 metre
Note:
The
M ovements
above
are
for
illustra$on
only
From
Bicheno
:
Lean
Games
Book.
Please
do
not
distribute.
In
84
TV News Game
85
93
96
97
1.
2.
3.
4.
AYer
Patrick
Graup
and
Robert
Wrona
From
Bicheno
:
Lean
Games
Book.
Please
The
TWI
Workbook,
Produc$vity
do
not
distribute.
98
99
Happy Pig
100
Standards
To
standardise
a
method
is
to
choose
out
of
many
methods
the
best
one,
and
use
it.
What
is
the
best
way
to
do
a
thing?
It
is
the
sum
of
all
the
good
ways
we
have
discovered
up
to
the
present.
It,
therefore
becomes
the
standard.
Todays
standardisa$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
101
102
103
Oval
Curve
Note
Alignment
Of
Ovals
Note
Construc$on
From
Bicheno
:
Lean
Games
Book.
Please
Lines
do
not
distribute.
Note Straight
104