The LeanMan

Exercise #1
Batch ‘n Queue Push - Dept 1

Stockroom:
1 Pick the batch of kits, placing the car bodies into a
large yellow tote container, and placing the remaining
material for each car into a plastic bag, zip lock the
bag and place each bag into large yellow container
with the car bodies.
2 Move the batch of cars to the next operation
3 Repeat kiting operation for next batch using the empty
containers when they are returned.

NOTE: randomly insert a painted wheel into one of the kits

until told to stop.

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Exercise #1
Batch ‘n Queue Push - Dept 2
Wheel / Axle subassembly:
1 Remove materials from containers. Return all
empty containers to the Stockroom.
3 Place the axle onto a fixture by pressing the
rounded hub into the fixtures recessed hole.
2 Assemble the wheel onto the axle.
4 Place 4 subassemblies onto each fixture.
5 Place remaining kit materials into a tote container.
6 Pass entire batch of loaded fixtures and tote
to the next department when complete.

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Exercise #1
Batch ‘n Queue Push - Dept 3
Car assembly:
1 Slip a disk brake over each axle, then remove each
wheel, brake & axle subassembly from the holding
fixture.
2 Attach the subassembly to car body, use clockwise
twist as you insert the axle peg.
Return empty holding fixtures and tote to previous
operation dept.
3 Move the completed batch of cars to the next
operation when all are complete.

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Exercise #1
Batch ‘n Queue Push – Dept 4
Inspection Criteria:
1 All 4 wheels should rotate freely.
2 All 4 wheels should be unpainted.
Return any reject to previous operation for repair,
tell the stock keeper to stop using painted wheels
3 If all cars are acceptable, move the completed cars
as a batch to the Finished Goods department.

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Exercise #1
Batch ‘n Queue Push - Dept 5
Finished Goods / Shipping
1 Receive completed batches of cars into FGI
2 Pay attention to the time, and at 4 minutes deliver
the first set of 3 cars to the customer.
3 Deliver a set of 3 cars every 4 minutes thereafter.

TPS Car Factory Simulation 1st Copyright © 2004 by The LeanMan, LLC 19
 The LeanMan

Exercise #1
Batch ‘n Queue Push - Dept 6
Conveyance/ Customer / Timekeeper
1 Timekeeper - Start the exercise by starting the
stopwatch and calling go.
2 If asked by the Team Leader, perform the task of
material mover. Move all materials between each
department when the need is apparent or when
called upon to do so.
3 When 4 minutes are up - call ‘4 minutes are up’ and
‘we are on overtime’ if there has not yet been a
customer delivery. Call STOP when the first delivery
is made or at the end of OT which ever comes first.
4 Complete the metrics sheet

TPS Car Factory Simulation 1st Copyright © 2004 by The LeanMan, LLC 20