Lego Exercise Part II

Lean State

Grow &
Innovate

Eliminate Reduce
Waste Variability

© 2003 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 1

 Module Objectives

• Re-connect to Lego exercise Part 1

• Recap week 1 tools and methodology

• Application of Lean Concepts

- Show future state
- Show single piece flow

© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 2

 Lean Principles
1) Specify value in the eyes of the customer
2) Identify the value stream and eliminate waste
3) Make value flow at the pull of the customer
4) Involve and empower employees
5) Continuously improve in pursuit of perfection

Flow Principles Look Ideal State:

at the Entire • Only Value Added
Process Steps/time
• Balanced flow
• No Scrap/Rework
• No Back Flows
• No Stoppages
Pack
Receiving Machining Assembly
and Ship • Continuous Flow

© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 3

 Using the Value Stream Mapping Tool

Focus on a specific product or part

Product/Process family to value stream
Family

Understanding how the process

currently operates. Learning to see the
Current State Map waste is the foundation for the future
state

Designing a Future State using

lean and variation reduction
Future State Map tools on the CSM to create flow
and eliminate waste

Develop 30/60/90 day

Implementatio Implementation Plan then
n Plan repeat the process

© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 4

 Standard Work
• Best, easiest, safest way you know today.
• Simple and conspicuous
• Documentation of know-how with input from
operations, quality, and engineering
• Consistent with quality, delivery, cost requirements
• Employees need not only be aware a standard exists,
but understand it and follow it! One standard at a
time.
• Results in balanced production with minimum
inventory and labor
• Focuses Management
• It is the basis for training
• It is the basis for audit and diagnosis
• Control variability
• Ensures sharing of “Best Practices”
© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 5
 Standard Work
Workstation: Engine Assy Method Sheet #2
Model – Red Car
2
1

Assemble (1) ea. head cover to top of each engine

block.

1a 3 3a

X 45 45
1b
2

Assemble (2) ea. Engine blocks to

the 4-peg base leaving 2 of the Note: Flare
base pegs uncovered. Engine Finished Assembly
heads must tilt outward. Engine Heads

© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 6

 Lean Simulation

Lean State Multimedia Projector and Flip

Chart
Computer

Training
Kit

Simulation Supplies
= Work In
Process
Kanban
= 2 Bin
Withdraw Rear Drive
Kanbans Train Assembly
= Method Sheet Forward
Chassis to
Rear Drive
train

Spoiler
Final
Assembly
Assembly

Engine
Assembly

© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 7

 Textron Mixed Model Build Sequence
Build Order # Model Type
1 Red Car
2 Blue Car
3 Red Car - no spoiler
4 Blue Car
5 Red Car
6 Blue Car - no spoiler
7 Red Car
8 Blue Car
9 Red Car
10 Blue Car
11 Red Car
12 Blue Car - no spoiler
13 Red Car
14 Blue Car

Blue Car
Spoiler -

Spoiler -
15 Red Car - no spoiler

Red Car
16 Blue Car
17
18
Red CarNo
Blue Car
19 Red Car

No
20 Blue Car - no spoiler
21 Red Car
22 Blue Car
23 Red Car - no spoiler
24 Blue Car
25 Red Car
26 Blue Car
27 Red Car
28 Blue Car - no spoiler
29 Red Car
30 Blue Car
31 Red Car - no spoiler
32 Blue Car
33 Red Car
34 Blue Car

© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 8

 2 Bin Withdraw Kanban Card
Part Number:
The part number and 330-9 Spoiler Mount
name in this bin

Quantity/bin:
12
How many parts to put
in the bin

Where the parts User location:

Spoiler Assy Station
are used

Supply location:
Materials Stockroom
Where the parts are
#5 stocked

Number of bins:
How many bins 2

© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 9

 Work In Process Kanban

Engine Kanban

© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 10

 Simulation Roles – Phase 2
1. Director of Operations
2. Stock Clerk 1
3. Expeditor 1
4. Forward Chassis
5. Rear Drive Train
6. Engine Build Up
7. Spoiler Assembly
8. Final Assembly
9. Time Keeper/WIP Data collector
10. Other Data gathering as directed by
the instructor

Instructor Picks Director of Operations, Director

of Operation Picks Team
© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 11
 Run Lean Simulation

© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 12

 Lego Simulation
Observations

© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 13

 Clean up

• Everyone needs to help take the Legos apart and

return parts to stock room
• Remember not to take apart models
• After everything is put away it is time to take a break

© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 14

 Lessons Learned/Pitfalls to Avoid
• Encourage Improvement
- Widespread orientation to CI, quality, training and
recruiting workers with appropriate skills
- Create common understanding of need to change to
lean
• Employee Involvement
- Push decision making to the appropriate team
member (Operator, support function, etc.)
- Trained and truly empowered people
• Share information and manage expectations
• Identify & empower champions, particularly
operation managers
- Remove roadblocks (i.e., people, layout, systems)
- Make it both directive yet empowering

© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 15

 Lessons Learned/Pitfalls to Avoid
• Atmosphere of Experimentation
- Work in a small groups (pilot) & expand with success
- Willingness to take risks (Safety nets)
• Installing “enlightened” and realistic performance
measures, evaluation, and reward systems
- Realign performance goals to meet new objectives
- Do measure results and not the number of
activities/events
- Tie improvements, long term, to key macro level
performance targets. (i.e. inventory turns, quality,
delivery, overall cost reductions).
• The need to execute pilot projects prior to rolling
culture out across organization is also essential
(e.g., model lines, kaizen blitzes)
- After early wins in operations, extend across ENTIRE
organization
© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 16
 Hints for Success
• Unyielding Leadership
• Benchmark outside successes and failures
• Define goals and objectives
• Start with pilot area (i.e., constraint operation, strong
commitment, easier deployment, considerable waste or
variation, process closest to customer, confined area, etc.)
• Form a team & improve communication
• Assess process & identify “Low Hanging Fruit (LHF)
Projects”
• Determine baseline to monitor improvements
• Develop a project timeline (include due dates & owners)
and begin with LHF projects
• Implement changes, monitor & adjust
• Continue improving area or target new processes
• Consider improving business or engineering processes

© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 17

 Key Learning Points

•
•
•
•
•
•

© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 18

 Module Objectives Revisited

• Re-connect to Lego exercise Part I

• Recap week 1 tools and methodology

• Application of Lean Concepts

- Show future state
- Show single piece flow

© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 19

 Configuration Management

Revision Date Author Description of Change

5.0 1/2005 Jeff Green Block Change Rewrite

© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 20