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The Lego Lean Game
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The Lego Lean Game

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  • I have a list of free Lean games and simulations on my blog at http://leansimulations.blogspot.com
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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

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