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The Lean Game
    Sneha Kadam
         @ichsneha
    ichsneha.blogspot.in
Why are we here?
     Ford’s conveyor belt - mass production system
                 “A Bomber an Hour” success


        ...
Eliminate Waste
          fundamental principle of Toyota Production System
                             - Taiichi Ohno


...

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The Lean Game

After revolutionizing the automobile industry, Lean principles have been successfully applied to different knowledge areas including software development. This workshop is intended to master Lean concepts like Waste, Push&Pull systems, systems thinking,Kaizen etc.! In this interactive game, the participants will work in a small Lego production line, experiencing problems and applying Lean practices to overcome them.

After revolutionizing the automobile industry, Lean principles have been successfully applied to different knowledge areas including software development. This workshop is intended to master Lean concepts like Waste, Push&Pull systems, systems thinking,Kaizen etc.! In this interactive game, the participants will work in a small Lego production line, experiencing problems and applying Lean practices to overcome them.

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The Lean Game

  1. 1. The Lean Game Sneha Kadam @ichsneha ichsneha.blogspot.in
  2. 2. Why are we here? Ford’s conveyor belt - mass production system “A Bomber an Hour” success Toyota’s lean production system “Just-In-Time” & “Kaizen” success Revolutionised Applied to different manufacturing areas software? I’m here to introduce you to Lean!
  3. 3. Eliminate Waste fundamental principle of Toyota Production System - Taiichi Ohno “anything that does not add value to the customer is waste” father of TPS Waste aka Muda
  4. 4. Eliminate Waste fundamental principle of Toyota Production System - Taiichi Ohno 7 Wastes of Manufacturing “anything Inventory that does not add value to the customer Extra processing is waste” Overproduction Transportation father of TPS Waiting Motion Defects - Shigeo Shingo Waste aka Muda Toyota Production System
  5. 5. Eliminate Waste fundamental principle of Toyota Production System - Taiichi Ohno 7 Wastes of Manufacturing “anything Inventory that does not add value to the customer Extra processing is waste” Overproduction Transportation father of TPS Waiting Motion Identify & eliminate waste Defects - Shigeo Shingo Waste aka Muda Toyota Production System
  6. 6. Hands On activity Retrospect 3 iterations Work in a Production Line Learn & Core Lean principles Adopt Lean in our world! What are we doing today?
  7. 7. Lets simulate a production line Station 1 Station 2 Station 4 Station 3
  8. 8. & build aLego House! & build a House of Lego
  9. 9. C home-builders B inventory inventory D inventory 2 3 1 4 + QA A inventory E inventory Follow instructions Build houses Sell to the Market Demand i say! “do what i want, not what Cost 1 lego brick = $1 1 house sold for = $25 Hands on : Iteration 1
  10. 10. Measuring Success
  11. 11. Inventory check C inventory Bunch of bricks of B inventory each colour, grouped D inventory by size Bunch of bricks of 1 set of bricks to build each colour house A inventory E inventory Bucket of Lego bricks Nothing.
  12. 12. Be a QUALITY Do it Worker RIGHT Take PRIDE in the your Work first time!! Stay Motivated!
  13. 13. Iteration #1 Lets play!
  14. 14. Go!
  15. 15. Stop!
  16. 16. Lets retrospect! what went well? what went wrong? how can we improve?
  17. 17. How many un-used Lego bricks? VS houses sold? Measuring Success
  18. 18. ste w a How many un-used Lego bricks? VS houses sold? Measuring Success
  19. 19. Predicted Mass Economies market demand production of scale What went wrong?
  20. 20. Predicted Mass Economies market demand production of scale What went wrong?
  21. 21. Predicted Mass Economies market demand production of scale What went wrong?
  22. 22. Push System - upstream information Predicted Mass Economies market demand production of scale “Any colour, as long as it’s black” - Henry Ford What went wrong?
  23. 23. Push System - upstream information Predicted Mass Economies market demand production of scale failed products! un-used by real-users “it sucked” “people became bored with it! Second life is as mundane as everyday life” ..relating to the software world
  24. 24. Adaptation On Demand Customer production requirements Learn & Adapt
  25. 25. Adaptation On Demand Customer production requirements Learn & Adapt
  26. 26. Adaptation On Demand Customer production requirements “Make only what is needed, only when it is needed, & only in the amount needed” - Kiichiro Toyoda Learn & Adapt
  27. 27. Pull System - downstream information Adaptation On Demand Customer production requirements “Make only what is needed, hy? only when it is needed, bu t w & only in the amount needed” - Kiichiro Toyoda Learn & Adapt
  28. 28. Pull System - downstream information Adaptation On Demand Customer production requirements “Make only what is needed, twhy? only when it is needed, b u & only in the amount needed” - Kiichiro Toyoda to build exactly what the market demands to avoid wasted inventory aka aka No Extra features avoid Partially done work ..relating to the software world
  29. 29. Push System Just-in-Case production - upstream information Predicted Mass Economies market production of scale Just-in-Time production Pull System - downstream information Adaptation On Demand Customer production requirements Pull vs Push Systems
  30. 30. Pull System - to avoid Overproduction Adaptation On Demand Customer production requirements Kanban 看板 means signboard/card, a signal to aid visual-control. Kanban helps Pull system
  31. 31. Pull System - to avoid Overproduction Adaptation On Demand Customer production requirements Kanban 看板 means signboard/card, a signal to aid visual-control. Kanban helps Pull system
  32. 32. C inventory B inventory D inventory station 2 station 3 station 1 + QA station 4 A inventory E inventory implement Pull system Demand comes first Market Demand “do what i want, not what i say! “ Hands on : Iteration 2
  33. 33. C inventory B inventory D inventory station 2 station 3 station 1 station 4 A inventory E inventory implement Kanban limit WIP i.e. build to fill gaps Pull system Demand comes first Market Demand “do what i want, not what i say! “ Hands on : Iteration 2
  34. 34. Inventory set-up C inventory 1 set of each colour B inventory D inventory 1 set of each colour 1 set of each colour A inventory E inventory Bucket of Lego bricks Nothing.
  35. 35. Be a QUALITY Do it Worker RIGHT Take PRIDE in the your Work first time!! Stay Motivated!
  36. 36. Iteration #2 Lets play!
  37. 37. Go!
  38. 38. Stop!
  39. 39. Lets retrospect!
  40. 40. What went well?
  41. 41. What went wrong?
  42. 42. Were you constantly working or were idle? Measuring Success
  43. 43. Were you constantly working or were idle? as te w Measuring Success
  44. 44. Mura aka Unevenness Some teams worked more while others waited.. ste w a What went wrong?
  45. 45. clear the bottleneck Goal is levelled process perform multiple tasks (instead of sitting idle) U-shaped work cell (Yatai) Learn & Adapt
  46. 46. achieve balance of skills Shokjinka generalist vs specialist multi skilled worker Learn & Adapt
  47. 47. Ready for Dev In Dev In QA (backlog) bug bug ..relating to the software world
  48. 48. Ready for Dev In Dev In QA (backlog) bug bug ..relating to the software world
  49. 49. Aids visual Ready for Dev In Dev In QA control 5 4 2 bug bug Limit WIP Signals demand pull system ..relating to the software world
  50. 50. Ready for Dev In Dev In QA 5 4 2 bug bug ..relating to the software world
  51. 51. dev, playing a qa when need arises Ready for Dev In Dev In QA 5 4 2 bug bug ..relating to the software world
  52. 52. C inventory B inventory D inventory station 2 station 3 station 1 station 4 A inventory E inventory Market Demand “do what i want, not what i say! “ implement Work Cell & self - organise Signal when you finish a house Hands on : Iteration 3
  53. 53. Build quality in! -Think about- levelling the workload Quality is everybody's responsibility!
  54. 54. Inventory set-up C inventory Bucket of Lego bricks B + D inventory house specs inventory Bucket of Lego bricks Bucket of Lego bricks + + house specs house specs A inventory E inventory Bucket of Lego bricks + Nothing. house specs
  55. 55. Be a QUALITY Do it Worker RIGHT Take PRIDE in the your Work first time!! Stay Motivated!
  56. 56. Iteration #3 Lets play!
  57. 57. Go!
  58. 58. Stop!
  59. 59. Lets retrospect! what went well? what went wrong? how can we improve?
  60. 60. How many houses did we sell? Measuring Success
  61. 61. Jidoka intelligent automation Stop the production line, to build quality in! Quality Assurance
  62. 62. Jidoka to raise productivity ke -yofing on oka proo P ror a nd Er Stop automatically if anything irregular occurs di ng oi Av ste Never produce defects wa Build it RIGHT the first time
  63. 63. andon Quality Assurance, in our world
  64. 64. simple tools to build quality in Go and See Analyse the situation One-piece flow & andon Ask 5 “Whys” Quality Assurance
  65. 65. Muda aka Waste 7 Wastes of Manufacturing Inventory Extra processing Overproduction Transportation Waiting Motion Defects - Shigeo Shingo Muda Toyota Production System
  66. 66. Muda aka Waste 7 Wastes of Manufacturing 7 Wastes of Software development Inventory Partially done work Extra processing Gold plating Overproduction Extra Features Transportation Task switching Waiting Waiting Motion Motion Defects Defects - Shigeo Shingo - Mary Poppendick Muda in our world Toyota Production System Lean Software Development
  67. 67. Thank you @ichsneha ichsneha.blogspot.in http://www.youtube.com/watch?feature=player_embedded&v=24PH9OCe4C8
  68. 68. The Lean Game Sneha Kadam @ichsneha ichsneha.blogspot.in

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