The Lean Game

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After revolutionizing the automobile industry, Lean principles have been successfully applied to different knowledge areas including software development. This workshop is intended to master Lean concepts like Waste, Push&Pull systems, systems thinking,Kaizen etc.! In this interactive game, the participants will work in a small Lego production line, experiencing problems and applying Lean practices to overcome them.

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  • The Lean Game

    1. 1. The Lean Game Sneha Kadam @ichsneha ichsneha.blogspot.in
    2. 2. Why are we here? Ford’s conveyor belt - mass production system “A Bomber an Hour” success Toyota’s lean production system “Just-In-Time” & “Kaizen” success Revolutionised Applied to different manufacturing areas software?I’m here to introduce you to Lean!
    3. 3. Eliminate Waste fundamental principle of Toyota Production System - Taiichi Ohno “anything that does not add value to the customer is waste” father of TPSWaste aka Muda
    4. 4. Eliminate Waste fundamental principle of Toyota Production System - Taiichi Ohno 7 Wastes of Manufacturing “anything Inventory that does not add value to the customer Extra processing is waste” Overproduction Transportation father of TPS Waiting Motion Defects - Shigeo ShingoWaste aka Muda Toyota Production System
    5. 5. Eliminate Waste fundamental principle of Toyota Production System - Taiichi Ohno 7 Wastes of Manufacturing “anything Inventory that does not add value to the customer Extra processing is waste” Overproduction Transportation father of TPS Waiting Motion Identify & eliminate waste Defects - Shigeo ShingoWaste aka Muda Toyota Production System
    6. 6. Hands On activity Retrospect 3 iterationsWork in a Production Line Learn &Core Lean principles AdoptLean in our world!What are we doing today?
    7. 7. Lets simulate a production line Station 1Station 2 Station 4 Station 3
    8. 8. & build aLego House! & build aHouse of Lego
    9. 9. Chome-builders B inventory inventory D inventory 2 3 1 4 + QA A inventory E inventory Follow instructions Build houses Sell to the Market Demand i say! “do what i want, not what Cost 1 lego brick = $1 1 house sold for = $25 Hands on : Iteration 1
    10. 10. Measuring Success
    11. 11. Inventory check C inventory Bunch of bricks of B inventory each colour, grouped D inventory by size Bunch of bricks of 1 set of bricks to build each colour house A inventory E inventoryBucket of Lego bricks Nothing.
    12. 12. Be a QUALITY Do it Worker RIGHT Take PRIDE in the your Work first time!!Stay Motivated!
    13. 13. Iteration #1Lets play!
    14. 14. Go!
    15. 15. Stop!
    16. 16. Lets retrospect! what went well? what went wrong? how can we improve?
    17. 17. How many un-used Lego bricks? VS houses sold?Measuring Success
    18. 18. ste w a How many un-used Lego bricks? VS houses sold?Measuring Success
    19. 19. Predicted Mass Economies market demand production of scaleWhat went wrong?
    20. 20. Predicted Mass Economies market demand production of scaleWhat went wrong?
    21. 21. Predicted Mass Economies market demand production of scaleWhat went wrong?
    22. 22. Push System - upstream information Predicted Mass Economies market demand production of scale “Any colour, as long as it’s black” - Henry FordWhat went wrong?
    23. 23. Push System - upstream information Predicted Mass Economies market demand production of scale failed products! un-used by real-users “it sucked” “people became bored with it! Second life is as mundane as everyday life”..relating to the software world
    24. 24. Adaptation On Demand Customer production requirementsLearn & Adapt
    25. 25. Adaptation On Demand Customer production requirementsLearn & Adapt
    26. 26. Adaptation On Demand Customer production requirements “Make only what is needed, only when it is needed, & only in the amount needed” - Kiichiro ToyodaLearn & Adapt
    27. 27. Pull System - downstream informationAdaptation On Demand Customer production requirements “Make only what is needed, hy? only when it is needed, bu t w & only in the amount needed” - Kiichiro ToyodaLearn & Adapt
    28. 28. Pull System - downstream informationAdaptation On Demand Customer production requirements “Make only what is needed, twhy? only when it is needed, b u & only in the amount needed” - Kiichiro Toyoda to build exactly what the market demands to avoid wasted inventory aka aka No Extra features avoid Partially done work..relating to the software world
    29. 29. Push System Just-in-Case production - upstream information Predicted Mass Economies market production of scale Just-in-Time production Pull System - downstream information Adaptation On Demand Customer production requirementsPull vs Push Systems
    30. 30. Pull System - to avoid Overproduction Adaptation On Demand Customer production requirements Kanban 看板 means signboard/card, a signal to aid visual-control.Kanban helps Pull system
    31. 31. Pull System - to avoid Overproduction Adaptation On Demand Customer production requirements Kanban 看板 means signboard/card, a signal to aid visual-control.Kanban helps Pull system
    32. 32. C inventory B inventory D inventory station 2 station 3 station 1 + QA station 4 A inventory E inventory implement Pull system Demand comes first Market Demand “do what i want, not what i say! “Hands on : Iteration 2
    33. 33. C inventory B inventory D inventory station 2 station 3 station 1 station 4 A inventory E inventory implement Kanban limit WIP i.e. build to fill gaps Pull system Demand comes first Market Demand “do what i want, not what i say! “Hands on : Iteration 2
    34. 34. Inventory set-up C inventory 1 set of each colour B inventory D inventory 1 set of each colour 1 set of each colour A inventory E inventoryBucket of Lego bricks Nothing.
    35. 35. Be a QUALITY Do it Worker RIGHT Take PRIDE in the your Work first time!!Stay Motivated!
    36. 36. Iteration #2Lets play!
    37. 37. Go!
    38. 38. Stop!
    39. 39. Lets retrospect!
    40. 40. What went well?
    41. 41. What went wrong?
    42. 42. Were you constantlyworking or were idle?Measuring Success
    43. 43. Were you constantlyworking or were idle? as te wMeasuring Success
    44. 44. Mura aka Unevenness Some teams worked more while others waited.. ste w aWhat went wrong?
    45. 45. clear the bottleneck Goal is levelled process perform multiple tasks (instead of sitting idle) U-shaped work cell (Yatai)Learn & Adapt
    46. 46. achieve balance of skills Shokjinka generalist vs specialist multi skilled workerLearn & Adapt
    47. 47. Ready for Dev In Dev In QA (backlog) bug bug..relating to the software world
    48. 48. Ready for Dev In Dev In QA (backlog) bug bug..relating to the software world
    49. 49. Aids visual Ready for Dev In Dev In QA control 5 4 2 bug bug Limit WIP Signals demand pull system..relating to the software world
    50. 50. Ready for Dev In Dev In QA 5 4 2 bug bug..relating to the software world
    51. 51. dev, playing a qa when need arises Ready for Dev In Dev In QA 5 4 2 bug bug..relating to the software world
    52. 52. C inventory B inventory D inventory station 2 station 3 station 1 station 4 A inventory E inventory Market Demand “do what i want, not what i say! “ implement Work Cell & self - organise Signal when you finish a houseHands on : Iteration 3
    53. 53. Build quality in! -Think about-levelling the workloadQuality is everybodysresponsibility!
    54. 54. Inventory set-up C inventory Bucket of Lego bricks B + D inventory house specs inventory Bucket of Lego bricks Bucket of Lego bricks + + house specs house specs A inventory E inventoryBucket of Lego bricks + Nothing. house specs
    55. 55. Be a QUALITY Do it Worker RIGHT Take PRIDE in the your Work first time!!Stay Motivated!
    56. 56. Iteration #3Lets play!
    57. 57. Go!
    58. 58. Stop!
    59. 59. Lets retrospect! what went well? what went wrong? how can we improve?
    60. 60. How many houses did we sell?Measuring Success
    61. 61. Jidoka intelligent automation Stop the production line, to build quality in!Quality Assurance
    62. 62. Jidoka to raise productivity ke -yofing on oka proo P ror a nd ErStop automatically if anything irregular occurs di ng oi Av ste Never produce defects wa Build it RIGHT the first time
    63. 63. andonQuality Assurance, in our world
    64. 64. simple tools to build quality in Go and See Analyse the situation One-piece flow & andon Ask 5 “Whys”Quality Assurance
    65. 65. Muda aka Waste 7 Wastes of Manufacturing Inventory Extra processing Overproduction Transportation Waiting Motion Defects - Shigeo ShingoMuda Toyota Production System
    66. 66. Muda aka Waste 7 Wastes of Manufacturing 7 Wastes of Software development Inventory Partially done work Extra processing Gold plating Overproduction Extra Features Transportation Task switching Waiting Waiting Motion Motion Defects Defects - Shigeo Shingo - Mary PoppendickMuda in our world Toyota Production System Lean Software Development
    67. 67. Thank you @ichsneha ichsneha.blogspot.inhttp://www.youtube.com/watch?feature=player_embedded&v=24PH9OCe4C8
    68. 68. The Lean Game Sneha Kadam @ichsneha ichsneha.blogspot.in

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