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The Lego Lean Game

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  • 1. The Lego Lean Game Danilo Sato, Francisco Trindade Agiles 2008 – Buenos Aires - Argentina
    • 22 nd Oct 2008
    © ThoughtWorks 2008
  • 2.
    • Quick introduction
    • Simulating a production line
    • How about software?
    Agenda © ThoughtWorks 2008
  • 3.
    • 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
  • 4.
    • 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
  • 5. Lean? © ThoughtWorks 2008
  • 6.
    • Push and Pull Systems
    • Kanban
    • Systems Thinking
    • Flow
    • Yatai (Work Cell)
    • And more…
    What we want to show © ThoughtWorks 2008
  • 7.
    • 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
  • 8. Stay Motivated! © ThoughtWorks 2008
  • 9.
    • What went wrong?
    Houston we have a problem… © ThoughtWorks 2008
  • 10.
    • Visible Inventory
    • Over/Under Production
    Waste © ThoughtWorks 2008
  • 11.
    • Overproduction
    • Waiting
    • Conveyance
    • Overprocessing
    • Inventory
    • Motion
    • Defects
    7 Wastes of Manufacturing © ThoughtWorks 2008
  • 12. Push and Pull Systems © ThoughtWorks 2008
    • Push System – upstream information
    • Pull System – downstream information
  • 13.
    • 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
  • 14. Kanban © ThoughtWorks 2008
  • 15.
    • 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
  • 16. Stay Motivated! © ThoughtWorks 2008
  • 17.
    • What went wrong?
    Houston we have a problem… © ThoughtWorks 2008
  • 18.
    • Another type of waste
    • Some people working more than others
    • Mura (Unevenness)
    • Heijunka
    • Balance number of people based on constraints
    Unleveled Process © ThoughtWorks 2008
  • 19.
    • 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
  • 20.
    • Multi-skilled worker
    • Single piece flow
    Yatai (Work Cell) © ThoughtWorks 2008
  • 21.
    • 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
  • 22. Stay Motivated! © ThoughtWorks 2008
  • 23.
    • 1 st Step - Push System
    • 2 nd Step - Pull System
    • 3 rd Step - Work Cell
    Our Results © ThoughtWorks 2008
  • 24.
    • We saw some of the practices
    • Practices are contextual
    • Underlying principles must be understood
      • Like agile!
    Is That All? © ThoughtWorks 2008
  • 25. 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
  • 26.
    • Continuous Improvement
    • Reflect and adapt
    • Learn by standardizing
    • Long term thinking
    • Respect People
    Kaizen © ThoughtWorks 2008
  • 27. Other Improvements? © ThoughtWorks 2008
  • 28.
    • 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
  • 29.
    • 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
  • 30.
    • Example: Push System in Software
    Lean in Software Development © ThoughtWorks 2008
  • 31.
    • Example: Pull System in Software
    Lean in Software Development © ThoughtWorks 2008
  • 32.
    • Example: Pull System in Software
    Lean in Software Development © ThoughtWorks 2008
  • 33.
    • 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
  • 34. Thank you! Questions? [email_address] [email_address] © ThoughtWorks 2008 dtsato.com franktrindade.com