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The Lean Lego Game
Francisco Trindade
Danilo Sato
Agenda
  Quick Introduction

  Simulating a production line

  How about software ?
Process
Debriefing

   Hands On




              Results



Process
Debriefing

   Hands On




              Results
                            3x
Process
Why ?
Lean concepts
 being used in the
 software world

 But without much contact
 with Lean principles and
 practices


Why ?
“... over the years there have been some
ostensibly ʻleanʼ promoters that reduced lean
thinking to a mechanistic superficia...
“... over the years there have been some
ostensibly ʻleanʼ promoters that reduced lean
thinking to a mechanistic superficia...
Lean
Toyota Production
     System
Revolutionized
manufacturing
Revolutionized     Applied to
manufacturing    different areas
What we want to show
Push


What we want to show
Push

          Pull
What we want to show
Push

          Pull
Flow

What we want to show
Push

          Pull
Flow
   Systems
      Thinking

What we want to show
Push

          Pull
Flow     Yatai
   Systems
      Thinking

What we want to show
Push

          Pull
Flow     Yatai
   Systems
      Thinking
            Heijunka
What we want to show
Hands on - 1st Step
Task 1   Task 2   Task 3   Task 4




Hands on - 1st Step
Task 1   Task 2   Task 3      Task 4


                            4 Teams
                           4 Rounds
           ...
Task 1      Task 2    Task 3   Task 4


         Follow the instructions
         Build houses
         1 Piece = $ 1.00
 ...
What went wrong ?




Houston, we have a problem...
Visible Inventory
Over/Under Production




Waste
Visible Inventory
Over/Under Production




Waste
Visible Inventory
Over/Under Production
                    700                       Task 4
                             ...
7 Wastes of Manufacturing
Overproduction




7 Wastes of Manufacturing
Overproduction

Waiting




7 Wastes of Manufacturing
Overproduction

Waiting

Overprocessing




7 Wastes of Manufacturing
Overproduction

Waiting

Overprocessing

Unnecessary
Transportation



7 Wastes of Manufacturing
Overproduction    Inventory

Waiting

Overprocessing

Unnecessary
Transportation



7 Wastes of Manufacturing
Overproduction    Inventory

Waiting           Motion

Overprocessing

Unnecessary
Transportation



7 Wastes of Manufactu...
Overproduction    Inventory

Waiting           Motion

Overprocessing    Defects

Unnecessary
Transportation



7 Wastes o...
Push and Pull Systems
Push




Push and Pull Systems
Push
  Expected
  Demand




Push and Pull Systems
Push
  Expected   Mass
  Demand     Production




Push and Pull Systems
Push
  Expected   Mass         Economies
  Demand     Production   of Scale




Push and Pull Systems
Push




Push and Pull Systems
Push



                     “Any colour, as
                   long as it’s black”
                               Henry F...
Push
  Expected   Mass         Economies
  Demand     Production   of Scale




Push and Pull Systems
Push
  Expected   Mass         Economies
  Demand     Production   of Scale




Pull




Push and Pull Systems
Push
  Expected   Mass         Economies
  Demand     Production   of Scale




Pull
                              Custome...
Push
  Expected   Mass             Economies
  Demand     Production       of Scale




Pull
                On Demand    ...
Push
  Expected          Mass             Economies
  Demand            Production       of Scale




Pull
               ...
Pull




Push and Pull Systems
Pull




Push and Pull Systems
TASK 1




Kanban
         TASK 2
TASK 1




Kanban
         TASK 2
TASK 1




Kanban
         TASK 2
TASK 1




Kanban
         TASK 2
Signals demand
                      Regulates demand
                      Limits Work in Process
    TASK 1




        ...
Signals demand
         Regulates demand
         Limits Work in Process
         Aids visual control
         Self-direct...
Signals demand
         Regulates demand
         Limits Work in Process
         Aids visual control
         Self-direct...
Pull System


Hands on - 2nd Step
Task 1   Task 2   Task 3   Task 4




   Pull System


Hands on - 2nd Step
Task 1   Task 2   Task 3      Task 4


                            4 Teams
   Pull System             4 Rounds
           ...
Task 1       Task 2       Task 3        Task 4


Pull System
   Setup minimum buffers at intermediate steps
   Demand come...
Task 1       Task 2       Task 3        Task 4


Pull System
   Setup minimum buffers at intermediate steps
   Demand come...
What went wrong ?




Houston, we have a problem...
Another type of waste
 Some people working more than others
 Mura (Unevenness)
 Heijunka




Unleveled Process
Goal is a leveled process
Production line must be a continuous flow
One piece is bought when one piece is delivered
Sustain...
Goal is a leveled process
Production line must be a continuous flow
One piece is bought when one piece is delivered
Sustain...
Goal is a leveled process
Production line must be a continuous flow
One piece is bought when one piece is delivered
Sustain...
http://www.youtube.com/watch?v=nq9SnHXIG00


Flow
Why does it still feel wrong?
  What are the other teams doing?
  What’s the purpose of the system?




Systems Thinking
“A bad system
                     will beat a
                    good person
                     every time”

         ...
Do we need 4 teams to build a house?
 Teams 1 and 2 have overlapping tasks




Systems Thinking
Multi-skilled worker
Single piece flow




Yatai (Work Cell)
Hands on - 3rd Step
Sell house    Build




Hands on - 3rd Step
Sell house     Build




Hands on - 3rd Step
Sell house                 Build



  Each person builds a house
  Round of 120 seconds
  Signal if you finish it



Hands ...
What went wrong ?




Houston, we have a problem...
Continuous Improvement
 Reflect and adapt
 Learn by standardizing
 Long term thinking
 Respect People




Kaizen
Continuous Improvement
 Reflect and adapt
 Learn by standardizing
 Long term thinking
 Respect People




Kaizen
Continuous Improvement
 Reflect and adapt
 Learn by standardizing
 Long term thinking
 Respect People

           “Toyota’s...
Is that all ?
Push System




Is that all ?
Push System


                Pull System




Is that all ?
Push System


                Pull System


                              Yatai




Is that all ?
Push System


                Pull System


                              Yatai


                         What’s next ?

...
Push System
                We saw some of the practices
  Pull System   Practices are contextual
                Principl...
What TPS is Not
         A recipe for success
         A management project or program
         A set of tools for impleme...
What TPS is
         A consistent way of thinking
         A total management philosophy
         Focus on total customer ...
Lean in Software Development
X
Lean in Software Development
Overproduction               Inventory

Waiting                      Motion

Overprocessing               Defects

Unneces...
Overproduction
Waiting
Unnecessary Transportation
Overprocessing
Inventory
Motion
Defects


Lean in Software Development
Overproduction
Waiting
Unnecessary Transportation
                             Overprocessing
                            ...
Extra Features             Overproduction
Waiting
Unnecessary Transportation
Gold Plating               Overprocessing
Par...
Kanban Board




Lean in Software Development
Kanban Board




Lean in Software Development
Kanban Board




Lean in Software Development
Controlling Kanban




       Do you have a stable process ?




Lean in Software Development
Controlling Kanban




Lean in Software Development
Controlling Kanban




Lean in Software Development
Controlling Kanban




Lean in Software Development
Controlling Kanban




Lean in Software Development
Much more:




Lean in Software Development
Much more:
 Eliminate Waste
 Create Knowledge
 Build Quality In
 Defer Commitment
 Deliver Fast
 Respect People
 Improve S...
Much more:
 Eliminate Waste    Genchi Genbutsu
 Create Knowledge   A3
 Build Quality In   5 Whys?
 Defer Commitment   Stop...
Lean in Software Development
X
Lean in Software Development
Agile Open Office
  http://connect.thoughtworks.com/agile2009/

TW One on One
 http://connect.thoughtworks.com/1on1



Some...
Thank You!
                            Questions ?



dsato@thoughtworks.com      dtsato.com          @dtsato
ftrindad@tho...
Lean Lego Game
Lean Lego Game
Lean Lego Game
Lean Lego Game
Lean Lego Game
Lean Lego Game
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Lean Lego Game

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

Published in: Technology, Sports
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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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