The Lego Lean Game

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Information about The Lego Lean Game

Published on December 22, 2008

Author: frankmt

Source: slideshare.net

The Lego Lean Game Danilo Sato, Francisco Trindade Agiles 2008 – Buenos Aires - Argentina 22 nd Oct 2008 © ThoughtWorks 2008

22 nd Oct 2008

Quick introduction Simulating a production line How about software? Agenda © ThoughtWorks 2008

Quick introduction

Simulating a production line

How about software?

Lean concepts starting to be noticed in the software world But not everyone has had contact with Lean principles and practices We’re here to introduce you to Lean Hands On! Why are we here? © ThoughtWorks 2008

Lean concepts starting to be noticed in the software world

But not everyone has had contact with Lean principles and practices

We’re here to introduce you to Lean

Hands On!

Toyota Production System Revolutionized manufacturing (Ford vs. Toyota) Started to be applied to different areas Google, Dell, Zara, … Product Development Supply Chain Management Software … Lean? © ThoughtWorks 2008

Toyota Production System

Revolutionized manufacturing (Ford vs. Toyota)

Started to be applied to different areas

Google, Dell, Zara, …

Product Development

Supply Chain Management

Software



Lean? © ThoughtWorks 2008

Push and Pull Systems Kanban Systems Thinking Flow Yatai (Work Cell) And more… What we want to show © ThoughtWorks 2008

Push and Pull Systems

Kanban

Systems Thinking

Flow

Yatai (Work Cell)

And more…

Let’s simulate a production line… Hands On – 1 st Step © ThoughtWorks 2008 4 Teams 4 rounds of 30 seconds (x2) Follow the instructions Build houses 1 Piece = $ 1.00 1 House = $ 25.00

Let’s simulate a production line…

4 Teams

4 rounds of 30 seconds (x2)

Follow the instructions

Build houses

1 Piece = $ 1.00

1 House = $ 25.00

Stay Motivated! © ThoughtWorks 2008

What went wrong? Houston we have a problem… © ThoughtWorks 2008

What went wrong?

Visible Inventory Over/Under Production Waste © ThoughtWorks 2008

Visible Inventory

Over/Under Production

Overproduction Waiting Conveyance Overprocessing Inventory Motion Defects 7 Wastes of Manufacturing © ThoughtWorks 2008

Overproduction

Waiting

Conveyance

Overprocessing

Inventory

Motion

Defects

Push and Pull Systems © ThoughtWorks 2008 Push System – upstream information Pull System – downstream information

Push System – upstream information

Pull System – downstream information

Physical device Signals demand to downstream processes Regulates demand on a pull system Limits Work in Process (WIP) Aids visual control Self-directing Kanban © ThoughtWorks 2008

Physical device

Signals demand to downstream processes

Regulates demand on a pull system

Limits Work in Process (WIP)

Aids visual control

Self-directing

Kanban © ThoughtWorks 2008

Using Pull and Kanban Setup minimum buffers at intermediate steps Demand comes first Items are produced to fill gaps in the buffers 4 rounds of 30 seconds (x2) Hands On – 2 nd Step © ThoughtWorks 2008

Using Pull and Kanban

Setup minimum buffers at intermediate steps

Demand comes first

Items are produced to fill gaps in the buffers

4 rounds of 30 seconds (x2)

Stay Motivated! © ThoughtWorks 2008

What went wrong? Houston we have a problem… © ThoughtWorks 2008

What went wrong?

Another type of waste Some people working more than others Mura (Unevenness) Heijunka Balance number of people based on constraints Unleveled Process © ThoughtWorks 2008

Another type of waste

Some people working more than others

Mura (Unevenness)

Heijunka

Balance number of people based on constraints

Why does it still feel wrong? What are the other teams doing? What’s the purpose of the system? Do we need 4 teams to build a house? Teams 1 and 2 have overlapping tasks Systems Thinking © ThoughtWorks 2008

Why does it still feel wrong?

What are the other teams doing?

What’s the purpose of the system?

Do we need 4 teams to build a house?

Teams 1 and 2 have overlapping tasks

Multi-skilled worker Single piece flow Yatai (Work Cell) © ThoughtWorks 2008

Multi-skilled worker

Single piece flow

Using Work Cells Each group will build 4 houses Each person builds the whole house Signal when all houses are built Hands On – 3 rd Step © ThoughtWorks 2008

Using Work Cells

Each group will build 4 houses

Each person builds the whole house

Signal when all houses are built

Stay Motivated! © ThoughtWorks 2008

1 st Step - Push System 2 nd Step - Pull System 3 rd Step - Work Cell Our Results © ThoughtWorks 2008

1 st Step - Push System

2 nd Step - Pull System

3 rd Step - Work Cell

We saw some of the practices Practices are contextual Underlying principles must be understood Like agile! Is That All? © ThoughtWorks 2008

We saw some of the practices

Practices are contextual

Underlying principles must be understood

Like agile!

Is That All? © ThoughtWorks 2008 Myth What TPS Is Not Reality What TPS Is A tangible recipe for success A consistent way of thinking A management project or program A total management philosophy A set of tools for implementation Focus on total customer satisfaction A system for production floor only An environment of teamwork and improvement Implementable in a short- or mid- term period A never ending search for a better way Quality built in process Evolutionary

Continuous Improvement Reflect and adapt Learn by standardizing Long term thinking Respect People Kaizen © ThoughtWorks 2008

Continuous Improvement

Reflect and adapt

Learn by standardizing

Long term thinking

Respect People

Other Improvements? © ThoughtWorks 2008

Manufacturing is not the same as Software Development Lean Product Development Knowledge flow is not the same as material flow Lean in Software Development © ThoughtWorks 2008

Manufacturing is not the same as Software Development

Lean Product Development

Knowledge flow is not the same as material flow

7 Wastes in Software Extra Features Waiting Unnecessary Transportation Gold Plating Partially Completed Work Unnecessary Movement Defects Unused Employee Creativity Lean in Software Development © ThoughtWorks 2008

7 Wastes in Software

Extra Features

Waiting

Unnecessary Transportation

Gold Plating

Partially Completed Work

Unnecessary Movement

Defects

Unused Employee Creativity

Example: Push System in Software Lean in Software Development © ThoughtWorks 2008

Example: Push System in Software

Example: Pull System in Software Lean in Software Development © ThoughtWorks 2008

Example: Pull System in Software

Example: Pull System in Software Lean in Software Development © ThoughtWorks 2008

Example: Pull System in Software

Much more: Eliminate Waste Create Knowledge Build Quality In Defer Commitment Deliver Fast Respect People Improve System You came to the wrong session  Lean in Software Development © ThoughtWorks 2008

Much more:

Eliminate Waste

Create Knowledge

Build Quality In

Defer Commitment

Deliver Fast

Respect People

Improve System

You came to the wrong session 

Thank you! Questions? [email_address] [email_address] © ThoughtWorks 2008 dtsato.com franktrindade.com

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