Lean Principles for Agile LEGO Exercise

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Exercise guide used as part of Lean Principles for Agile workshop.

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Lean Principles for Agile LEGO Exercise

  1. 1. Lean Principles for Agile Teams “LEGO” Building Block Exercise Feb 10, 2014 Elizabeth Woodward Lean and Agile Strategist evwoodwa@us.ibm.com
  2. 2. Requirements For this exercise with 3 teams, you can use two boxes of Lakeshore Best-Buy Building Bricks RA401. They come in plastic tubs with some extra larger pieces that we don’t use for this exercise, so I remove them. These building blocks don’t stick together quite as well as LEGOs, but they worked for the purpose. For traveling, I combined all of the building bricks into one of the plastic tubs and was able to fit the plastic tub into a carry-on with room for extra supplies. I also purchased stacks of play money to provide compensation. Print out a set of the steps below for each team on a color printer. Check the darkness of the printout and make sure that participants can see the individual building blocks. Print out station labels on heavy paper or card stock and fold in half. Round 1. This will demonstrate several issues related to waste and uneven flow. Set up the room as follows: 1. Put the supplies far away, crisscross the stations. Label stations by team: • • • • • • • Team 1 Station 1 Team 1 Station 2 Team 1 Station 3 Team 1 Station 4 Team 1 Station 5 Team 1 Station 6 Team 1 Station 7 2. Put the cards for the steps at each station. You can modify the steps per station to accommodate the number of people in the class. There needs to be at least one station with a lot more work than the others. 3. Put the raw parts across the room in a difficult to reach place. 4. Announce: a. Each station is individually compensated for each item that you are able to produce. b. You are only allowed to do the work for your step. c. Part of your job involves getting the raw parts that you need. This work is licensed under the Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-sa/3.0/ or send a letter to Creative Commons, 444 Castro Street, Suite 900, Mountain View, California, 94041, USA.
  3. 3. d. Last step is QA. If an error is found, QA will identify who made the mistake and only that person can fix their mistake. e. We’ll call when time is up. Ready, set, go. (Call time after a couple of items have been built.) Discuss Observations. You should hear things like: • • • • • • Materials are too far apart (Muda waste of motion) Workspace is confused (Muda waste of motion) There are bottlenecks (Mura, uneveness) and high stress for some (Muri) QA is impacted at the end (Muda) Some people had nothing to do (Muda waste of waiting) Notice the waste of parts, extra stuff has been produced (Muda waste of inventory) This work is licensed under the Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-sa/3.0/ or send a letter to Creative Commons, 444 Castro Street, Suite 900, Mountain View, California, 94041, USA.
  4. 4. Round 2. This round we’re going to reduce the waste of motion and unevenness. Set up the room as follows: 1. Ask teams to put Legos back in the box and rearrange their stations so they are more streamlined. They can redistribute the cards at each station to improve flow. 2. Announce: a. Each team member is compensated for what they are able to produce without regard for what anyone else is doing. b. Anyone who notices a problem can raise the issue and fix the problem. c. We’ll call when time is up. Ready, set, go. (Call time after a couple of items have been built.) Emphasize: Congratulate the individual person who produced the most components. Discuss Observations. You should hear things like: • • • • Less waste of motion now that stations are in order (Muda waste of motion) Workspace is less confused (Muda waste of motion) Reduced bottlenecks (Mura, uneveness) and less stress for some (Muri) Better QA Plan, Do, Check, Act and Scientific Method. Typically would not introduce a large number of changes at once. • What can happen if we introduce a large number of changes at the same time in the work environment? This work is licensed under the Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-sa/3.0/ or send a letter to Creative Commons, 444 Castro Street, Suite 900, Mountain View, California, 94041, USA.
  5. 5. Round 3. This round we’re going to reduce the waste of motion and unevenness and limit work in progress. Set up the room as follows: 1. Ask teams to put Legos back in the box and rearrange their stations so they are more streamlined. They can redistribute the cards at each station to improve flow if needed. 2. Announce: a. Each team is only compensated for the whole and we are going to subtract for any waste. b. Team decides how they are going to limit work in progress. (Ie, can a station have more than 1 item completed and waiting on the next?) c. Anyone who notices a problem can raise the issue and fix the problem. d. Team members can help each other. e. We’ll call when time is up. Ready, set, go. (Call time after a couple of items have been built.) Emphasize: The number of completed items. Discuss Observations. What change might you introduce next? This work is licensed under the Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-sa/3.0/ or send a letter to Creative Commons, 444 Castro Street, Suite 900, Mountain View, California, 94041, USA.
  6. 6. • Vision This work is licensed under the Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-sa/3.0/ or send a letter to Creative Commons, 444 Castro Street, Suite 900, Mountain View, California, 94041, USA.
  7. 7. Step 1 Use two white 2x12 Step 2 Use three 4x13 yellow pieces and hold them together with the white 2x12’s. This work is licensed under the Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-sa/3.0/ or send a letter to Creative Commons, 444 Castro Street, Suite 900, Mountain View, California, 94041, USA.
  8. 8. Step 3 NOTE: You will have an extra row of yellow nibs on one side. Count the bumps. This work is licensed under the Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-sa/3.0/ or send a letter to Creative Commons, 444 Castro Street, Suite 900, Mountain View, California, 94041, USA.
  9. 9. You will add all red and blue pieces. White and yellow have been assembled for you. This work is licensed under the Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-sa/3.0/ or send a letter to Creative Commons, 444 Castro Street, Suite 900, Mountain View, California, 94041, USA.
  10. 10. Step 4 This work is licensed under the Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-sa/3.0/ or send a letter to Creative Commons, 444 Castro Street, Suite 900, Mountain View, California, 94041, USA.
  11. 11. Step 5 This work is licensed under the Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-sa/3.0/ or send a letter to Creative Commons, 444 Castro Street, Suite 900, Mountain View, California, 94041, USA.
  12. 12. Create the Topper with steps 6 and 7. Step 6 Step 7 This work is licensed under the Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-sa/3.0/ or send a letter to Creative Commons, 444 Castro Street, Suite 900, Mountain View, California, 94041, USA.
  13. 13. Step 8 Combine two parts—Base and Topper This work is licensed under the Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-sa/3.0/ or send a letter to Creative Commons, 444 Castro Street, Suite 900, Mountain View, California, 94041, USA.
  14. 14. This work is licensed under the Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-sa/3.0/ or send a letter to Creative Commons, 444 Castro Street, Suite 900, Mountain View, California, 94041, USA.
  15. 15. Step 9. Put the plastic man on top of the structure. This work is licensed under the Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-sa/3.0/ or send a letter to Creative Commons, 444 Castro Street, Suite 900, Mountain View, California, 94041, USA.
  16. 16. Step 10 QA Compare against the vision If there is an error, only the person who created that part can fix it. This work is licensed under the Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-sa/3.0/ or send a letter to Creative Commons, 444 Castro Street, Suite 900, Mountain View, California, 94041, USA.

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