Lean Lego Game

The Lean Lego Game Francisco Trindade Danilo Sato

Agenda Quick Introduction Simulating a production line How about software ?

Process

Debrieﬁng Hands On Results Process

Debrieﬁng Hands On Results 3x Process

Lean concepts being used in the software world But without much contact with Lean principles and practices Why ?

“... over the years there have been some ostensibly ʻleanʼ promoters that reduced lean thinking to a mechanistic superﬁcial level of management tools such as kanban and queue management. ... the essence of successful lean thinking is building people, then building products and a culture of “challenge the status quo continuous improvement ” Lean Primer (http://tinyurl.com/owvhut)

“... over the years there have been some ostensibly ʻleanʼ promoters that reduced lean thinking to a mechanistic superﬁcial level of management tools such as kanban and queue management. ... the essence of successful lean thinking is building people, then building products and a culture of “challenge the status quo continuous improvement ” Lean Primer (http://tinyurl.com/owvhut) We’re here to introduce you to Lean

Toyota Production System

Revolutionized manufacturing

Revolutionized Applied to manufacturing different areas

What we want to show

Push What we want to show

Push Pull What we want to show

Push Pull Flow What we want to show

Push Pull Flow Systems Thinking What we want to show

Push Pull Flow Yatai Systems Thinking What we want to show

Push Pull Flow Yatai Systems Thinking Heijunka What we want to show

Hands on - 1st Step

Task 1 Task 2 Task 3 Task 4 Hands on - 1st Step

Task 1 Task 2 Task 3 Task 4 4 Teams 4 Rounds 30 secs Hands on - 1st Step

Task 1 Task 2 Task 3 Task 4 Follow the instructions Build houses 1 Piece = $ 1.00 1 House = $ 25.00 Hands on - 1st Step

What went wrong ? Houston, we have a problem...

Visible Inventory Over/Under Production Waste

Visible Inventory Over/Under Production 700 Task 4 Task 3 Task 2 525 Task 1 350 175 0 0 1 2 3 4 Waste

7 Wastes of Manufacturing

Overproduction 7 Wastes of Manufacturing

Overproduction Waiting 7 Wastes of Manufacturing

Overproduction Waiting Overprocessing 7 Wastes of Manufacturing

Overproduction Waiting Overprocessing Unnecessary Transportation 7 Wastes of Manufacturing

Overproduction Inventory Waiting Overprocessing Unnecessary Transportation 7 Wastes of Manufacturing

Overproduction Inventory Waiting Motion Overprocessing Unnecessary Transportation 7 Wastes of Manufacturing

Overproduction Inventory Waiting Motion Overprocessing Defects Unnecessary Transportation 7 Wastes of Manufacturing

Push and Pull Systems

Push Push and Pull Systems

Push Expected Demand Push and Pull Systems

Push Expected Mass Demand Production Push and Pull Systems

Push Expected Mass Economies Demand Production of Scale Push and Pull Systems

Push Push and Pull Systems

Push “Any colour, as long as it’s black” Henry Ford Push and Pull Systems

Push Expected Mass Economies Demand Production of Scale Push and Pull Systems

Push Expected Mass Economies Demand Production of Scale Pull Push and Pull Systems

Push Expected Mass Economies Demand Production of Scale Pull Customer Requirements Push and Pull Systems

Push Expected Mass Economies Demand Production of Scale Pull On Demand Customer Production Requirements Push and Pull Systems

Push Expected Mass Economies Demand Production of Scale Pull On Demand Customer Adaptation Production Requirements Push and Pull Systems

Pull Push and Pull Systems

TASK 1 Kanban TASK 2

Signals demand Regulates demand Limits Work in Process TASK 1 TASK 2 Aids visual control Self-directing Kanban

Signals demand Regulates demand Limits Work in Process Aids visual control Self-directing Kanban

Pull System Hands on - 2nd Step

Task 1 Task 2 Task 3 Task 4 Pull System Hands on - 2nd Step

Task 1 Task 2 Task 3 Task 4 4 Teams Pull System 4 Rounds 30 secs Hands on - 2nd Step

Task 1 Task 2 Task 3 Task 4 Pull System Setup minimum buffers at intermediate steps Demand comes ﬁrst Items are produced to ﬁll gaps in the buffers Hands on - 2nd Step

Task 1 Task 2 Task 3 Task 4 Pull System Setup minimum buffers at intermediate steps Demand comes ﬁrst nban Ka Items are produced to ﬁll gaps in the buffers Hands on - 2nd Step

Another type of waste Some people working more than others Mura (Unevenness) Heijunka Unleveled Process

Goal is a leveled process Production line must be a continuous ﬂow One piece is bought when one piece is delivered Sustainable pace Flow

Goal is a leveled process Production line must be a continuous ﬂow One piece is bought when one piece is delivered Sustainable pace Flow Watch the baton, not the ru nners rimer (http://tiny Lean P url.com/owvhut)

http://www.youtube.com/watch?v=nq9SnHXIG00 Flow

Why does it still feel wrong? What are the other teams doing? What’s the purpose of the system? Systems Thinking

“A bad system will beat a good person every time” W. Eduards Deming Systems Thinking

Do we need 4 teams to build a house? Teams 1 and 2 have overlapping tasks Systems Thinking

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

Hands on - 3rd Step

Sell house Build Hands on - 3rd Step

Sell house Build Each person builds a house Round of 120 seconds Signal if you ﬁnish it Hands on - 3rd Step

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

Continuous Improvement Reﬂect and adapt Learn by standardizing Long term thinking Respect People “Toyota’s real ad vantage was its ability to harness the inte llect of ‘ordinary’ employees” Gary Hamel Kaizen

Is that all ?

Push System Is that all ?

Push System Pull System Is that all ?

Push System Pull System Yatai Is that all ?

Push System Pull System Yatai What’s next ? Is that all ?

Push System We saw some of the practices Pull System Practices are contextual Principles must be understood Yatai Is that all ?

What TPS is Not A recipe for success A management project or program A set of tools for implementation A system for production ﬂoor only Implementable in a short- or mid- term period What is Lean ?

What TPS is A consistent way of thinking A total management philosophy Focus on total customer satisfaction An environment of teamwork and improvement A never ending search for a better way What is Lean ?

Lean in Software Development

X Lean in Software Development

Overproduction Inventory Waiting Motion Overprocessing Defects Unnecessary Transportation Lean in Software Development

Overproduction Waiting Unnecessary Transportation Overprocessing Inventory Motion Defects Lean in Software Development

Extra Features Overproduction Waiting Unnecessary Transportation Gold Plating Overprocessing Partially Completed Work Inventory Motion Defects Unused Employee Creativity Lean in Software Development

Kanban Board Lean in Software Development

Controlling Kanban Do you have a stable process ? Lean in Software Development

Controlling Kanban Lean in Software Development

Much more: Lean in Software Development

Much more: Eliminate Waste Create Knowledge Build Quality In Defer Commitment Deliver Fast Respect People Improve System Lean in Software Development

Much more: Eliminate Waste Genchi Genbutsu Create Knowledge A3 Build Quality In 5 Whys? Defer Commitment Stop the Line Deliver Fast Andon Respect People Jidoka Improve System Mistake Prooﬁng Lean in Software Development

Lean in Software Development

X Lean in Software Development

Agile Open Ofﬁce http://connect.thoughtworks.com/agile2009/ TW One on One http://connect.thoughtworks.com/1on1 Something extra...

Thank You! Questions ? dsato@thoughtworks.com dtsato.com @dtsato ftrindad@thoughtworks.com franktrindade.com @frankmt

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Lean Lego Game

by Danilo Sato

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