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The Lego Lean Game

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The Lego Lean Game

  1. 1. The Lego Lean Game Danilo Sato, Francisco Trindade Agiles 2008 – Buenos Aires - Argentina <ul><li>22 nd Oct 2008 </li></ul>© ThoughtWorks 2008
  2. 2. <ul><li>Quick introduction </li></ul><ul><li>Simulating a production line </li></ul><ul><li>How about software? </li></ul>Agenda © ThoughtWorks 2008
  3. 3. <ul><li>Lean concepts starting to be noticed in the software world </li></ul><ul><li>But not everyone has had contact with Lean principles and practices </li></ul><ul><li>We’re here to introduce you to Lean </li></ul><ul><li>Hands On! </li></ul>Why are we here? © ThoughtWorks 2008
  4. 4. <ul><li>Toyota Production System </li></ul><ul><ul><li>Revolutionized manufacturing (Ford vs. Toyota) </li></ul></ul><ul><ul><li>Started to be applied to different areas </li></ul></ul><ul><ul><ul><li>Google, Dell, Zara, … </li></ul></ul></ul><ul><ul><ul><li>Product Development </li></ul></ul></ul><ul><ul><ul><li>Supply Chain Management </li></ul></ul></ul><ul><ul><ul><li>Software </li></ul></ul></ul><ul><ul><ul><li>… </li></ul></ul></ul>Lean? © ThoughtWorks 2008
  5. 5. Lean? © ThoughtWorks 2008
  6. 6. <ul><li>Push and Pull Systems </li></ul><ul><li>Kanban </li></ul><ul><li>Systems Thinking </li></ul><ul><li>Flow </li></ul><ul><li>Yatai (Work Cell) </li></ul><ul><li>And more… </li></ul>What we want to show © ThoughtWorks 2008
  7. 7. <ul><li>Let’s simulate a production line… </li></ul>Hands On – 1 st Step © ThoughtWorks 2008 <ul><li>4 Teams </li></ul><ul><li>4 rounds of 30 seconds (x2) </li></ul><ul><li>Follow the instructions </li></ul><ul><li>Build houses </li></ul><ul><li>1 Piece = $ 1.00 </li></ul><ul><li>1 House = $ 25.00 </li></ul>
  8. 8. Stay Motivated! © ThoughtWorks 2008
  9. 9. <ul><li>What went wrong? </li></ul>Houston we have a problem… © ThoughtWorks 2008
  10. 10. <ul><li>Visible Inventory </li></ul><ul><li>Over/Under Production </li></ul>Waste © ThoughtWorks 2008
  11. 11. <ul><li>Overproduction </li></ul><ul><li>Waiting </li></ul><ul><li>Conveyance </li></ul><ul><li>Overprocessing </li></ul><ul><li>Inventory </li></ul><ul><li>Motion </li></ul><ul><li>Defects </li></ul>7 Wastes of Manufacturing © ThoughtWorks 2008
  12. 12. Push and Pull Systems © ThoughtWorks 2008 <ul><li>Push System – upstream information </li></ul><ul><li>Pull System – downstream information </li></ul>
  13. 13. <ul><li>Physical device </li></ul><ul><li>Signals demand to downstream processes </li></ul><ul><li>Regulates demand on a pull system </li></ul><ul><li>Limits Work in Process (WIP) </li></ul><ul><li>Aids visual control </li></ul><ul><li>Self-directing </li></ul>Kanban © ThoughtWorks 2008
  14. 14. Kanban © ThoughtWorks 2008
  15. 15. <ul><li>Using Pull and Kanban </li></ul><ul><ul><li>Setup minimum buffers at intermediate steps </li></ul></ul><ul><ul><li>Demand comes first </li></ul></ul><ul><ul><li>Items are produced to fill gaps in the buffers </li></ul></ul><ul><li>4 rounds of 30 seconds (x2) </li></ul>Hands On – 2 nd Step © ThoughtWorks 2008
  16. 16. Stay Motivated! © ThoughtWorks 2008
  17. 17. <ul><li>What went wrong? </li></ul>Houston we have a problem… © ThoughtWorks 2008
  18. 18. <ul><li>Another type of waste </li></ul><ul><li>Some people working more than others </li></ul><ul><li>Mura (Unevenness) </li></ul><ul><li>Heijunka </li></ul><ul><li>Balance number of people based on constraints </li></ul>Unleveled Process © ThoughtWorks 2008
  19. 19. <ul><li>Why does it still feel wrong? </li></ul><ul><li>What are the other teams doing? </li></ul><ul><li>What’s the purpose of the system? </li></ul><ul><li>Do we need 4 teams to build a house? </li></ul><ul><li>Teams 1 and 2 have overlapping tasks </li></ul>Systems Thinking © ThoughtWorks 2008
  20. 20. <ul><li>Multi-skilled worker </li></ul><ul><li>Single piece flow </li></ul>Yatai (Work Cell) © ThoughtWorks 2008
  21. 21. <ul><li>Using Work Cells </li></ul><ul><ul><li>Each group will build 4 houses </li></ul></ul><ul><ul><li>Each person builds the whole house </li></ul></ul><ul><ul><li>Signal when all houses are built </li></ul></ul>Hands On – 3 rd Step © ThoughtWorks 2008
  22. 22. Stay Motivated! © ThoughtWorks 2008
  23. 23. <ul><li>1 st Step - Push System </li></ul><ul><li>2 nd Step - Pull System </li></ul><ul><li>3 rd Step - Work Cell </li></ul>Our Results © ThoughtWorks 2008
  24. 24. <ul><li>We saw some of the practices </li></ul><ul><li>Practices are contextual </li></ul><ul><li>Underlying principles must be understood </li></ul><ul><ul><li>Like agile! </li></ul></ul>Is That All? © ThoughtWorks 2008
  25. 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. 26. <ul><li>Continuous Improvement </li></ul><ul><li>Reflect and adapt </li></ul><ul><li>Learn by standardizing </li></ul><ul><li>Long term thinking </li></ul><ul><li>Respect People </li></ul>Kaizen © ThoughtWorks 2008
  27. 27. Other Improvements? © ThoughtWorks 2008
  28. 28. <ul><li>Manufacturing is not the same as Software Development </li></ul><ul><li>Lean Product Development </li></ul><ul><ul><li>Knowledge flow is not the same as material flow </li></ul></ul>Lean in Software Development © ThoughtWorks 2008
  29. 29. <ul><li>7 Wastes in Software </li></ul><ul><ul><li>Extra Features </li></ul></ul><ul><ul><li>Waiting </li></ul></ul><ul><ul><li>Unnecessary Transportation </li></ul></ul><ul><ul><li>Gold Plating </li></ul></ul><ul><ul><li>Partially Completed Work </li></ul></ul><ul><ul><li>Unnecessary Movement </li></ul></ul><ul><ul><li>Defects </li></ul></ul><ul><ul><li>Unused Employee Creativity </li></ul></ul>Lean in Software Development © ThoughtWorks 2008
  30. 30. <ul><li>Example: Push System in Software </li></ul>Lean in Software Development © ThoughtWorks 2008
  31. 31. <ul><li>Example: Pull System in Software </li></ul>Lean in Software Development © ThoughtWorks 2008
  32. 32. <ul><li>Example: Pull System in Software </li></ul>Lean in Software Development © ThoughtWorks 2008
  33. 33. <ul><li>Much more: </li></ul><ul><ul><li>Eliminate Waste </li></ul></ul><ul><ul><li>Create Knowledge </li></ul></ul><ul><ul><li>Build Quality In </li></ul></ul><ul><ul><li>Defer Commitment </li></ul></ul><ul><ul><li>Deliver Fast </li></ul></ul><ul><ul><li>Respect People </li></ul></ul><ul><ul><li>Improve System </li></ul></ul><ul><li>You came to the wrong session  </li></ul>Lean in Software Development © ThoughtWorks 2008
  34. 34. Thank you! Questions? [email_address] [email_address] © ThoughtWorks 2008 dtsato.com franktrindade.com

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