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Lean Lego Game

Lean Lego Game, presented in Aug/2009 at Agile 2009 in Chicago

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Lean Lego Game

  1. 1. The Lean Lego Game Francisco Trindade Danilo Sato
  2. 2. Agenda Quick Introduction Simulating a production line How about software ?
  3. 3. Process
  4. 4. Debriefing Hands On Results Process
  5. 5. Debriefing Hands On Results 3x Process
  6. 6. Why ?
  7. 7. Lean concepts being used in the software world But without much contact with Lean principles and practices Why ?
  8. 8. “... over the years there have been some ostensibly ʻleanʼ promoters that reduced lean thinking to a mechanistic superficial level of management tools such as kanban and queue management. ... the essence of successful lean thinking is building people, then building products and a culture of “challenge the status quo continuous improvement ” Lean Primer (http://tinyurl.com/owvhut)
  9. 9. “... over the years there have been some ostensibly ʻleanʼ promoters that reduced lean thinking to a mechanistic superficial level of management tools such as kanban and queue management. ... the essence of successful lean thinking is building people, then building products and a culture of “challenge the status quo continuous improvement ” Lean Primer (http://tinyurl.com/owvhut) We’re here to introduce you to Lean
  10. 10. Lean
  11. 11. Toyota Production System
  12. 12. Revolutionized manufacturing
  13. 13. Revolutionized Applied to manufacturing different areas
  14. 14. What we want to show
  15. 15. Push What we want to show
  16. 16. Push Pull What we want to show
  17. 17. Push Pull Flow What we want to show
  18. 18. Push Pull Flow Systems Thinking What we want to show
  19. 19. Push Pull Flow Yatai Systems Thinking What we want to show
  20. 20. Push Pull Flow Yatai Systems Thinking Heijunka What we want to show
  21. 21. Hands on - 1st Step
  22. 22. Task 1 Task 2 Task 3 Task 4 Hands on - 1st Step
  23. 23. Task 1 Task 2 Task 3 Task 4 4 Teams 4 Rounds 30 secs Hands on - 1st Step
  24. 24. Task 1 Task 2 Task 3 Task 4 Follow the instructions Build houses 1 Piece = $ 1.00 1 House = $ 25.00 Hands on - 1st Step
  25. 25. What went wrong ? Houston, we have a problem...
  26. 26. Visible Inventory Over/Under Production Waste
  27. 27. Visible Inventory Over/Under Production Waste
  28. 28. Visible Inventory Over/Under Production 700 Task 4 Task 3 Task 2 525 Task 1 350 175 0 0 1 2 3 4 Waste
  29. 29. 7 Wastes of Manufacturing
  30. 30. Overproduction 7 Wastes of Manufacturing
  31. 31. Overproduction Waiting 7 Wastes of Manufacturing
  32. 32. Overproduction Waiting Overprocessing 7 Wastes of Manufacturing
  33. 33. Overproduction Waiting Overprocessing Unnecessary Transportation 7 Wastes of Manufacturing
  34. 34. Overproduction Inventory Waiting Overprocessing Unnecessary Transportation 7 Wastes of Manufacturing
  35. 35. Overproduction Inventory Waiting Motion Overprocessing Unnecessary Transportation 7 Wastes of Manufacturing
  36. 36. Overproduction Inventory Waiting Motion Overprocessing Defects Unnecessary Transportation 7 Wastes of Manufacturing
  37. 37. Push and Pull Systems
  38. 38. Push Push and Pull Systems
  39. 39. Push Expected Demand Push and Pull Systems
  40. 40. Push Expected Mass Demand Production Push and Pull Systems
  41. 41. Push Expected Mass Economies Demand Production of Scale Push and Pull Systems
  42. 42. Push Push and Pull Systems
  43. 43. Push “Any colour, as long as it’s black” Henry Ford Push and Pull Systems
  44. 44. Push Expected Mass Economies Demand Production of Scale Push and Pull Systems
  45. 45. Push Expected Mass Economies Demand Production of Scale Pull Push and Pull Systems
  46. 46. Push Expected Mass Economies Demand Production of Scale Pull Customer Requirements Push and Pull Systems
  47. 47. Push Expected Mass Economies Demand Production of Scale Pull On Demand Customer Production Requirements Push and Pull Systems
  48. 48. Push Expected Mass Economies Demand Production of Scale Pull On Demand Customer Adaptation Production Requirements Push and Pull Systems
  49. 49. Pull Push and Pull Systems
  50. 50. Pull Push and Pull Systems
  51. 51. TASK 1 Kanban TASK 2
  52. 52. TASK 1 Kanban TASK 2
  53. 53. TASK 1 Kanban TASK 2
  54. 54. TASK 1 Kanban TASK 2
  55. 55. Signals demand Regulates demand Limits Work in Process TASK 1 TASK 2 Aids visual control Self-directing Kanban
  56. 56. Signals demand Regulates demand Limits Work in Process Aids visual control Self-directing Kanban
  57. 57. Signals demand Regulates demand Limits Work in Process Aids visual control Self-directing Kanban
  58. 58. Pull System Hands on - 2nd Step
  59. 59. Task 1 Task 2 Task 3 Task 4 Pull System Hands on - 2nd Step
  60. 60. Task 1 Task 2 Task 3 Task 4 4 Teams Pull System 4 Rounds 30 secs Hands on - 2nd Step
  61. 61. Task 1 Task 2 Task 3 Task 4 Pull System Setup minimum buffers at intermediate steps Demand comes first Items are produced to fill gaps in the buffers Hands on - 2nd Step
  62. 62. Task 1 Task 2 Task 3 Task 4 Pull System Setup minimum buffers at intermediate steps Demand comes first nban Ka Items are produced to fill gaps in the buffers Hands on - 2nd Step
  63. 63. What went wrong ? Houston, we have a problem...
  64. 64. Another type of waste Some people working more than others Mura (Unevenness) Heijunka Unleveled Process
  65. 65. Goal is a leveled process Production line must be a continuous flow One piece is bought when one piece is delivered Sustainable pace Flow
  66. 66. Goal is a leveled process Production line must be a continuous flow One piece is bought when one piece is delivered Sustainable pace Flow Watch the baton, not the ru nners rimer (http://tiny Lean P url.com/owvhut)
  67. 67. Goal is a leveled process Production line must be a continuous flow One piece is bought when one piece is delivered Sustainable pace Flow Watch the baton, not the ru nners rimer (http://tiny Lean P url.com/owvhut)
  68. 68. http://www.youtube.com/watch?v=nq9SnHXIG00 Flow
  69. 69. Why does it still feel wrong? What are the other teams doing? What’s the purpose of the system? Systems Thinking
  70. 70. “A bad system will beat a good person every time” W. Eduards Deming Systems Thinking
  71. 71. Do we need 4 teams to build a house? Teams 1 and 2 have overlapping tasks Systems Thinking
  72. 72. Multi-skilled worker Single piece flow Yatai (Work Cell)
  73. 73. Hands on - 3rd Step
  74. 74. Sell house Build Hands on - 3rd Step
  75. 75. Sell house Build Hands on - 3rd Step
  76. 76. Sell house Build Each person builds a house Round of 120 seconds Signal if you finish it Hands on - 3rd Step
  77. 77. What went wrong ? Houston, we have a problem...
  78. 78. Continuous Improvement Reflect and adapt Learn by standardizing Long term thinking Respect People Kaizen
  79. 79. Continuous Improvement Reflect and adapt Learn by standardizing Long term thinking Respect People Kaizen
  80. 80. Continuous Improvement Reflect and adapt Learn by standardizing Long term thinking Respect People “Toyota’s real ad vantage was its ability to harness the inte llect of ‘ordinary’ employees” Gary Hamel Kaizen
  81. 81. Is that all ?
  82. 82. Push System Is that all ?
  83. 83. Push System Pull System Is that all ?
  84. 84. Push System Pull System Yatai Is that all ?
  85. 85. Push System Pull System Yatai What’s next ? Is that all ?
  86. 86. Push System We saw some of the practices Pull System Practices are contextual Principles must be understood Yatai Is that all ?
  87. 87. What TPS is Not A recipe for success A management project or program A set of tools for implementation A system for production floor only Implementable in a short- or mid- term period What is Lean ?
  88. 88. What TPS is A consistent way of thinking A total management philosophy Focus on total customer satisfaction An environment of teamwork and improvement A never ending search for a better way What is Lean ?
  89. 89. Lean in Software Development
  90. 90. X Lean in Software Development
  91. 91. Overproduction Inventory Waiting Motion Overprocessing Defects Unnecessary Transportation Lean in Software Development
  92. 92. Overproduction Waiting Unnecessary Transportation Overprocessing Inventory Motion Defects Lean in Software Development
  93. 93. Overproduction Waiting Unnecessary Transportation Overprocessing Inventory Motion Defects Lean in Software Development
  94. 94. Extra Features Overproduction Waiting Unnecessary Transportation Gold Plating Overprocessing Partially Completed Work Inventory Motion Defects Unused Employee Creativity Lean in Software Development
  95. 95. Kanban Board Lean in Software Development
  96. 96. Kanban Board Lean in Software Development
  97. 97. Kanban Board Lean in Software Development
  98. 98. Controlling Kanban Do you have a stable process ? Lean in Software Development
  99. 99. Controlling Kanban Lean in Software Development
  100. 100. Controlling Kanban Lean in Software Development
  101. 101. Controlling Kanban Lean in Software Development
  102. 102. Controlling Kanban Lean in Software Development
  103. 103. Much more: Lean in Software Development
  104. 104. Much more: Eliminate Waste Create Knowledge Build Quality In Defer Commitment Deliver Fast Respect People Improve System Lean in Software Development
  105. 105. Much more: Eliminate Waste Genchi Genbutsu Create Knowledge A3 Build Quality In 5 Whys? Defer Commitment Stop the Line Deliver Fast Andon Respect People Jidoka Improve System Mistake Proofing Lean in Software Development
  106. 106. Lean in Software Development
  107. 107. X Lean in Software Development
  108. 108. Agile Open Office http://connect.thoughtworks.com/agile2009/ TW One on One http://connect.thoughtworks.com/1on1 Something extra...
  109. 109. Thank You! Questions ? dsato@thoughtworks.com dtsato.com @dtsato ftrindad@thoughtworks.com franktrindade.com @frankmt

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