Kaizen Lego Game

Kaizen LegoGame Francisco Trindade (@frankmt) Patrick Kua (@patkua) Danilo Sato (@dtsato)

Who are we ?

Lean Lego Game “We want to make it be er!”Why ?

“The illiterate of the 21st century will not be those who cannot read and write, but those who cannot learn, unlearn, and relearn.” Alvin ToﬄerContinuous ImprovementWhat ?

Continuous Improvement Value Stream Mapping Inventory Standards Kaizen 5 Whys CFDCycle Time Waste Genchi GenbutsuWhat ?

Kaizen

Kai = Change and Zen = Good/Be er;together Kaizen stands for a smallmethodical continuous improvement stepsthat should be implemented daily .leancor.com/index.php Continuously improving in incremental steps. leanmfgsolutions.com/glossary.html literally translates to ‘continuous improvement’ in English. Kaizen activities are small, incremental activities performed over time where Kaikaku a radical and one- oﬀ. .richarddurnall.com /deﬁne Kaizen

Toyota Production SystemKaizen

Toyota Production System Applied to diﬀerent areas (including so ware...)Kaizen

Applied to diﬀerent areas (including so ware...) The Toyota Way 2001 Continuous Respect For Improvement PeopleKaizen Challenge Kaizen Genchi Gembutsu Respect Teamwork

The Toyota Way 2001 Continuous Respect For Improvement People Challenge Kaizen Genchi Respect Teamwork GembutsuNot only practices, but also principlesKaizen

Plan Do Act CheckHow are we doing this ?

Introduce improve standards concepts Run adapt Process Evaluate measureHow are we doing this ?

2 trackers buildersHow are we doing this ?

Inventory 2 trackers Cycle Time buildersHow are we doing this ?

Inventory How much are we spending ?Cycle Time How fast are we delivering ?How are we doing this ?

1st IterationAnd here we go...

Retail Price = $25.00 1 Lego Piece = $01.00 1 Seal = 13 pieces 13.00 + 12.00Some context

Trial & StandardAnd here we go...

2x 03:00And here we go...

Deliver! Build Seal QA Buy Pieces Cycle Time Tracker Inventory TrackerHow are we doing this ?

Deliver! Build Seal QA Buy Pieces How much are How long are we spending ? we taking ? Cycle Time Tracker Inventory TrackerHow are we doing this ?

Deliver! Build Seal QA Buy Pieces How can we improve ? Cycle Time Tracker Inventory TrackerHow are we doing this ?

Remember: G re e n Work for the card!How are we doing this ?

“The most dangerous kind of waste is the waste we do not recognize.” Shigeo ShingoWaste (Muda)

Overproduction Waiting Overprocessing Unnecessary Transportation Inventory Motion DefectsWaste (Muda)

“The foundation of the Toyota wayis based upon the simple yetelusive goal of identifying and Overproductioneliminating waste in all workactivities” Jeﬀrey Liker, The Toyota Way Fieldbook Waiting Overprocessing Unnecessary Transportation Inventory Motion DefectsWaste (Muda)

“Where there is no standard, there can be no improvement. For these reasons, standards are the basis for both maintenance and improvement.” Masaaki ImaiStandards & Improvement

“Data is of course important in manufacturing, but I place the greatest emphasis on facts.” Taiichi OhnoGenchi Genbutsu

“My car will not start.”5 Whys

“The ba ery Why? “My car will is dead” not start.” Why? “The alternator is not functioning.” “I have not been maintaining my car Why? according to the recommended schedule.” “The alternator belt has broken.” Why? “The alternator belt was well beyond its useful Why? service life and has never been replaced.”5 Whys

For want of a nail a shoe was lost,for want of a shoe a horse was lost,for want of a horse a rider was lost,for want of a rider an army was lost,for want of an army a ba le was lost,for want of a ba le the war was lost,for want of the war the kingdom was lost,and all for the want of a li le horseshoe nail. John Gowers Confesio Amantis dated approximately 1390 AD.5 Whys

2nd IterationAnd here we go again...

5 Why’sAnd here we go again...

5 Why’s Why didn’t we make any proﬁt ?And here we go again...

7:00 Analyse the problem 1:00 Create new standard 3:00 Run it againAnd here we go again...

ThinkingTime!

How didit go ?

time from concept to cashValue Stream Mapping

Finance MarketingOﬀice Admin CustomerCustomer Care Sales

“I want a seal!” Buy BuildPieces QA seal

“I want a seal!” Buy BuildPieces QA seal “My seal came in the wrong colour, I want a new one...”

Value “I want a seal!” Buy BuildPieces QA seal “My seal came in the wrong colour, I want a new one...”

Value “I want a seal!” Buy BuildPieces QA seal “My seal came in the wrong Failure colour, I want a new one...”

Point of Transaction Buy Build Pieces QA seal

Buy BuildPieces QA seal Demand: 1 Seal/30 sec Capability: 1 Seal/45 sec

Buy Build Pieces QA sealControl Chart Capability: 1 Seal/30-45 secTime Orders

As is Buy Build Pieces QA sealTo be ? ? ?

3rd IterationAnd here we go again...

Value Stream MappingAnd here we go again...

Value Stream Mapping As is process To be processAnd here we go again...

7:00 Analyse the problem 1:00 Create new standard 3:00 Run it againAnd here we go again...

ThinkingTime!

How didit go ?

Continuous Improvement It’s not just Reﬂect and adapt about Learn by standardizing practices Long term thinking Respect People “Toyota’s real advantage was its ability to harness the intellect of ‘ordinary’ employees” Gary HamelA erthoughts

Kaizen Lego GameA erthoughts

Thank you!Francisco Trindade (@frankmt) rindad@thoughtworks.comPatrick Kua (@patkua) pkua@thoughtworks.comDanilo Sato (@dtsato) dsato@thoughtworks.comQuestions?

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Kaizen Lego Game

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