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The Lego Lean Game (XP 2009 version)

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Version of the Lego Lean Game presented at XP 2009 in Sardinia, Italy.

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The Lego Lean Game (XP 2009 version)

  1. 1. The Lego Lean Game Danilo Sato, Francisco Trindade XP 2009 – Sardinia - Italy 25th May 2009 © ThoughtWorks 2008
  2. 2. Agenda • Quick introduction • Simulating a production line Hands On Debriefing • How about software? Results © ThoughtWorks 2008
  3. 3. Why are we here? • Lean concepts starting to be noticed in the software world • But not everyone has had contact with Lean principles and practices We’re here to introduce you to Lean Hands On! © ThoughtWorks 2008
  4. 4. Lean? • Toyota Production System – Revolutionized manufacturing (Ford vs. Toyota) – Started to be applied to different areas • Google, Dell, Zara, … • Product Development • Supply Chain Management • Software • Healthcare • … © ThoughtWorks 2008
  5. 5. Lean? © ThoughtWorks 2008
  6. 6. What we want to show • Push and Pull Systems • Kanban • Systems Thinking • Flow • Heijunka • Yatai (Work Cell) • And more… © ThoughtWorks 2008
  7. 7. Hands On – 1st Step • Let’s simulate a production line… Task 1 Task 2 Task 3 Task 4 Sell house • 4 Teams • Follow the instructions • 4 rounds of 40 seconds • Build houses • 1 Piece = $ 1.00 • 1 House = $ 25.00 © ThoughtWorks 2008
  8. 8. Stay Motivated! © ThoughtWorks 2008
  9. 9. Houston we have a problem… What went wrong? © ThoughtWorks 2008
  10. 10. Waste • Visible Inventory • Over/Under Production © ThoughtWorks 2008
  11. 11. 7 Wastes of Manufacturing • Overproduction • Waiting • Unnecessary Transportation • Overprocessing • Inventory • Motion • Defects © ThoughtWorks 2008
  12. 12. Push and Pull Systems • Push System – upstream information Expected Mass Economies Demand Production of Scale © ThoughtWorks 2008
  13. 13. Push and Pull Systems • Push System – upstream information Expected Mass Economies Demand Production of Scale © ThoughtWorks 2008
  14. 14. Push and Pull Systems • Push System – upstream information Expected Mass Economies Demand Production of Scale • Pull System – downstream information On Demand Customer Adaptation Production Requirements © ThoughtWorks 2008
  15. 15. Kanban • Physical device • Signals demand to downstream processes • Regulates demand on a pull system • Limits Work in Process (WIP) • Aids visual control • Self-directing © ThoughtWorks 2008
  16. 16. Kanban Process B Process A Idle Working Buffer Full © ThoughtWorks 2008
  17. 17. Kanban Process B Process A Idle Working Buffer Kanban © ThoughtWorks 2008
  18. 18. Kanban Process B Process A Working Working Buffer © ThoughtWorks 2008
  19. 19. Kanban Process B Process A Idle Working Buffer Full © ThoughtWorks 2008
  20. 20. Hands On – 2nd Step • Using Pull and Kanban – Setup minimum buffers at intermediate steps – Demand comes first – Items are produced to fill gaps in the buffers Sell house Task 4 Task 3 Task 2 Task 1 • 4 rounds of 40 seconds © ThoughtWorks 2008
  21. 21. Stay Motivated! © ThoughtWorks 2008
  22. 22. Houston we have a problem… What went wrong? © ThoughtWorks 2008
  23. 23. Unleveled Process • Another type of waste • Some people working more than others • Mura (Unevenness) • Heijunka © ThoughtWorks 2008
  24. 24. Flow • Final goal is a leveled process • Production line must be a continuous flow • One piece is bought when one piece is delivered • Sustainable pace © ThoughtWorks 2008
  25. 25. Systems Thinking • Why does it still feel wrong? • What are the other teams doing? • What’s the purpose of the system? © ThoughtWorks 2008
  26. 26. Systems Thinking • Why does it still feel wrong? • What are the other teams doing? • What’s the purpose of the system? © ThoughtWorks 2008
  27. 27. Let’s Experiment • Do we need 4 teams to build a house? • Teams 1 and 2 have overlapping tasks © ThoughtWorks 2008
  28. 28. Yatai (Work Cell) • Multi-skilled worker • Single piece flow © ThoughtWorks 2008
  29. 29. Hands On – 3rd Step • Using Work Cells – Each person builds a house – Round of 160 seconds – Signal (raise your hand) if you finish your house Sell house Build! © ThoughtWorks 2008
  30. 30. Stay Motivated! © ThoughtWorks 2008
  31. 31. Houston we have a problem… What went wrong? © ThoughtWorks 2008
  32. 32. Kaizen • Continuous Improvement • Reflect and adapt Plan Do • Learn by standardizing • Long term thinking Act Check • Respect People © ThoughtWorks 2008
  33. 33. Kaizen • Continuous Improvement • Reflect and adapt Plan Do • Learn by standardizing • Long term thinking Act Check • Respect People © ThoughtWorks 2008
  34. 34. Improving the Process It’s your turn to help ? us improve the ? process © ThoughtWorks 2008
  35. 35. Hands On – 4th Step • Discuss your own process Team Team • 1 round for each 1 2 team Team Team 3 4 © ThoughtWorks 2008
  36. 36. Stay Motivated! © ThoughtWorks 2008
  37. 37. Our Results Push System Kanban Yatai Team’s Process © ThoughtWorks 2008
  38. 38. Is That All? • We saw some of the practices • Practices are contextual • Underlying principles must be understood – Like agile! © ThoughtWorks 2008
  39. 39. What is Lean? Myth Reality What TPS Is Not 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- A never ending search for a better term period way Quality built in process Evolutionary © ThoughtWorks 2008
  40. 40. Lean in Software Development • Manufacturing is not the same as Software Development • Lean Product Development – Knowledge flow is not the same as material flow © ThoughtWorks 2008
  41. 41. Lean in Software Development • Extra Features (Overproduction) • Waiting (Waiting) • Unnecessary Transportation (Unnecessary Transportation) • Gold Plating (Overprocessing) • Partially Completed Work (Inventory) • Unnecessary Movement (Motion) • Defects (Defects) • Unused Employee Creativity © ThoughtWorks 2008
  42. 42. Lean in Software Development • Example: Push System in Software © ThoughtWorks 2008
  43. 43. Lean in Software Development • Example: Pull System in Software © ThoughtWorks 2008
  44. 44. Lean in Software Development • Example: Pull System in Software © ThoughtWorks 2008
  45. 45. Kanban In Ready for Ready for Ready for To Do In Dev In Test Done Analysis Dev Test Showcase © ThoughtWorks 2008
  46. 46. Kanban In Ready for Ready for Ready for To Do In Dev In Test Done Analysis Dev Test Showcase © ThoughtWorks 2008
  47. 47. Lean in Software Development • Much more: • Lean: – Eliminate Waste – GenchiGembutsu – Create Knowledge – A3 – Build Quality In – 5 Whys? – Defer Commitment – Stop the Line – Deliver Fast – Andon – Respect People – Jidoka – Improve System – Mistake Proofing © ThoughtWorks 2008
  48. 48. Thank you! Questions? dsato@thoughtworks.com dtsato.com ftrindad@thoughtworks.com franktrindade.com © ThoughtWorks 2008

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