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The Lean Game    Sneha Kadam         @ichsneha    ichsneha.blogspot.in
Why are we here?     Ford’s conveyor belt - mass production system                 “A Bomber an Hour” success           To...
Eliminate Waste          fundamental principle of Toyota Production System                             - Taiichi Ohno     ...
Eliminate Waste          fundamental principle of Toyota Production System                             - Taiichi Ohno     ...
Eliminate Waste          fundamental principle of Toyota Production System                             - Taiichi Ohno     ...
Hands On                            activity                                                     Retrospect               ...
Lets simulate a production line            Station 1Station 2                          Station 4        Station 3
& build aLego House!      & build aHouse of Lego
Chome-builders            B                      inventory                                      inventory                 ...
Measuring Success
Inventory check                                    C                                 inventory                           B...
Be a  QUALITY           Do it   Worker                   RIGHT                                Take PRIDE in               ...
Iteration #1Lets play!
Go!
Stop!
Lets retrospect!    what went well?   what went wrong?  how can we improve?
How many un-used     Lego bricks?            VS      houses sold?Measuring Success
ste	            w       a  How many un-used      Lego bricks?            VS      houses sold?Measuring Success
Predicted        Mass        Economies   market demand   production     of scaleWhat went wrong?
Predicted        Mass        Economies   market demand   production     of scaleWhat went wrong?
Predicted        Mass        Economies   market demand   production     of scaleWhat went wrong?
Push System                     - upstream information   Predicted            Mass                  Economies   market dem...
Push System                          - upstream information    Predicted                Mass                   Economies  ...
Adaptation      On Demand     Customer                 production   requirementsLearn & Adapt
Adaptation      On Demand     Customer                 production   requirementsLearn & Adapt
Adaptation        On Demand            Customer                    production          requirements            “Make only ...
Pull System                  - downstream informationAdaptation       On Demand                   Customer                ...
Pull System                             - downstream informationAdaptation                On Demand                       ...
Push System    Just-in-Case      production                         - upstream information        Predicted            Mas...
Pull System                      - to avoid Overproduction      Adaptation        On Demand                 Customer      ...
Pull System                        - to avoid Overproduction      Adaptation          On Demand                 Customer  ...
C                                   inventory              B           inventory                                          ...
C                                   inventory              B           inventory                                          ...
Inventory set-up                                    C                                 inventory                           ...
Be a  QUALITY           Do it   Worker                   RIGHT                                Take PRIDE in               ...
Iteration #2Lets play!
Go!
Stop!
Lets retrospect!
What went well?
What went wrong?
Were you constantlyworking or were idle?Measuring Success
Were you constantlyworking or were idle?                        as te	                    wMeasuring Success
Mura aka Unevenness             Some teams worked more               while others waited..                                ...
clear the bottleneck                               Goal is levelled process     perform   multiple tasks   (instead of sit...
achieve balance of skills                    Shokjinka  generalist     vs  specialist                multi skilled workerL...
Ready for Dev      In Dev   In QA             (backlog)                                              bug                  ...
Ready for Dev      In Dev   In QA             (backlog)                                              bug                  ...
Aids visual          Ready for Dev      In Dev          In QA           control                5               4          ...
Ready for Dev      In Dev   In QA                5              4        2                                              bu...
dev, playing a qa                                         when need arises          Ready for Dev      In Dev     In QA   ...
C                                        inventory              B           inventory                                     ...
Build quality in! -Think about-levelling the workloadQuality is everybodysresponsibility!
Inventory set-up                                     C                                  inventory                         ...
Be a  QUALITY           Do it   Worker                   RIGHT                                Take PRIDE in               ...
Iteration #3Lets play!
Go!
Stop!
Lets retrospect!    what went well?   what went wrong?  how can we improve?
How many houses did      we sell?Measuring Success
Jidoka                intelligent automation               Stop the production line,                  to build quality in!...
Jidoka               to raise productivity                                          ke	                                   ...
andonQuality Assurance, in our world
simple tools                     to build quality in                        Go and See                    Analyse the situ...
Muda aka Waste   7 Wastes of Manufacturing                   Inventory            Extra processing            Overproducti...
Muda aka Waste     7 Wastes of Manufacturing 7 Wastes of Software development                      Inventory              ...
Thank you              @ichsneha                   ichsneha.blogspot.inhttp://www.youtube.com/watch?feature=player_embedde...
The Lean Game    Sneha Kadam         @ichsneha    ichsneha.blogspot.in
The Lean Game
The Lean Game
The Lean Game
The Lean Game
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The Lean Game

After revolutionizing the automobile industry, Lean principles have been successfully applied to different knowledge areas including software development. This workshop is intended to master Lean concepts like Waste, Push&Pull systems, systems thinking,Kaizen etc.! In this interactive game, the participants will work in a small Lego production line, experiencing problems and applying Lean practices to overcome them.

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The Lean Game

  1. 1. The Lean Game Sneha Kadam @ichsneha ichsneha.blogspot.in
  2. 2. Why are we here? Ford’s conveyor belt - mass production system “A Bomber an Hour” success Toyota’s lean production system “Just-In-Time” & “Kaizen” success Revolutionised Applied to different manufacturing areas software?I’m here to introduce you to Lean!
  3. 3. Eliminate Waste fundamental principle of Toyota Production System - Taiichi Ohno “anything that does not add value to the customer is waste” father of TPSWaste aka Muda
  4. 4. Eliminate Waste fundamental principle of Toyota Production System - Taiichi Ohno 7 Wastes of Manufacturing “anything Inventory that does not add value to the customer Extra processing is waste” Overproduction Transportation father of TPS Waiting Motion Defects - Shigeo ShingoWaste aka Muda Toyota Production System
  5. 5. Eliminate Waste fundamental principle of Toyota Production System - Taiichi Ohno 7 Wastes of Manufacturing “anything Inventory that does not add value to the customer Extra processing is waste” Overproduction Transportation father of TPS Waiting Motion Identify & eliminate waste Defects - Shigeo ShingoWaste aka Muda Toyota Production System
  6. 6. Hands On activity Retrospect 3 iterationsWork in a Production Line Learn &Core Lean principles AdoptLean in our world!What are we doing today?
  7. 7. Lets simulate a production line Station 1Station 2 Station 4 Station 3
  8. 8. & build aLego House! & build aHouse of Lego
  9. 9. Chome-builders B inventory inventory D inventory 2 3 1 4 + QA A inventory E inventory Follow instructions Build houses Sell to the Market Demand i say! “do what i want, not what Cost 1 lego brick = $1 1 house sold for = $25 Hands on : Iteration 1
  10. 10. Measuring Success
  11. 11. Inventory check C inventory Bunch of bricks of B inventory each colour, grouped D inventory by size Bunch of bricks of 1 set of bricks to build each colour house A inventory E inventoryBucket of Lego bricks Nothing.
  12. 12. Be a QUALITY Do it Worker RIGHT Take PRIDE in the your Work first time!!Stay Motivated!
  13. 13. Iteration #1Lets play!
  14. 14. Go!
  15. 15. Stop!
  16. 16. Lets retrospect! what went well? what went wrong? how can we improve?
  17. 17. How many un-used Lego bricks? VS houses sold?Measuring Success
  18. 18. ste w a How many un-used Lego bricks? VS houses sold?Measuring Success
  19. 19. Predicted Mass Economies market demand production of scaleWhat went wrong?
  20. 20. Predicted Mass Economies market demand production of scaleWhat went wrong?
  21. 21. Predicted Mass Economies market demand production of scaleWhat went wrong?
  22. 22. Push System - upstream information Predicted Mass Economies market demand production of scale “Any colour, as long as it’s black” - Henry FordWhat went wrong?
  23. 23. Push System - upstream information Predicted Mass Economies market demand production of scale failed products! un-used by real-users “it sucked” “people became bored with it! Second life is as mundane as everyday life”..relating to the software world
  24. 24. Adaptation On Demand Customer production requirementsLearn & Adapt
  25. 25. Adaptation On Demand Customer production requirementsLearn & Adapt
  26. 26. Adaptation On Demand Customer production requirements “Make only what is needed, only when it is needed, & only in the amount needed” - Kiichiro ToyodaLearn & Adapt
  27. 27. Pull System - downstream informationAdaptation On Demand Customer production requirements “Make only what is needed, hy? only when it is needed, bu t w & only in the amount needed” - Kiichiro ToyodaLearn & Adapt
  28. 28. Pull System - downstream informationAdaptation On Demand Customer production requirements “Make only what is needed, twhy? only when it is needed, b u & only in the amount needed” - Kiichiro Toyoda to build exactly what the market demands to avoid wasted inventory aka aka No Extra features avoid Partially done work..relating to the software world
  29. 29. Push System Just-in-Case production - upstream information Predicted Mass Economies market production of scale Just-in-Time production Pull System - downstream information Adaptation On Demand Customer production requirementsPull vs Push Systems
  30. 30. Pull System - to avoid Overproduction Adaptation On Demand Customer production requirements Kanban 看板 means signboard/card, a signal to aid visual-control.Kanban helps Pull system
  31. 31. Pull System - to avoid Overproduction Adaptation On Demand Customer production requirements Kanban 看板 means signboard/card, a signal to aid visual-control.Kanban helps Pull system
  32. 32. C inventory B inventory D inventory station 2 station 3 station 1 + QA station 4 A inventory E inventory implement Pull system Demand comes first Market Demand “do what i want, not what i say! “Hands on : Iteration 2
  33. 33. C inventory B inventory D inventory station 2 station 3 station 1 station 4 A inventory E inventory implement Kanban limit WIP i.e. build to fill gaps Pull system Demand comes first Market Demand “do what i want, not what i say! “Hands on : Iteration 2
  34. 34. Inventory set-up C inventory 1 set of each colour B inventory D inventory 1 set of each colour 1 set of each colour A inventory E inventoryBucket of Lego bricks Nothing.
  35. 35. Be a QUALITY Do it Worker RIGHT Take PRIDE in the your Work first time!!Stay Motivated!
  36. 36. Iteration #2Lets play!
  37. 37. Go!
  38. 38. Stop!
  39. 39. Lets retrospect!
  40. 40. What went well?
  41. 41. What went wrong?
  42. 42. Were you constantlyworking or were idle?Measuring Success
  43. 43. Were you constantlyworking or were idle? as te wMeasuring Success
  44. 44. Mura aka Unevenness Some teams worked more while others waited.. ste w aWhat went wrong?
  45. 45. clear the bottleneck Goal is levelled process perform multiple tasks (instead of sitting idle) U-shaped work cell (Yatai)Learn & Adapt
  46. 46. achieve balance of skills Shokjinka generalist vs specialist multi skilled workerLearn & Adapt
  47. 47. Ready for Dev In Dev In QA (backlog) bug bug..relating to the software world
  48. 48. Ready for Dev In Dev In QA (backlog) bug bug..relating to the software world
  49. 49. Aids visual Ready for Dev In Dev In QA control 5 4 2 bug bug Limit WIP Signals demand pull system..relating to the software world
  50. 50. Ready for Dev In Dev In QA 5 4 2 bug bug..relating to the software world
  51. 51. dev, playing a qa when need arises Ready for Dev In Dev In QA 5 4 2 bug bug..relating to the software world
  52. 52. C inventory B inventory D inventory station 2 station 3 station 1 station 4 A inventory E inventory Market Demand “do what i want, not what i say! “ implement Work Cell & self - organise Signal when you finish a houseHands on : Iteration 3
  53. 53. Build quality in! -Think about-levelling the workloadQuality is everybodysresponsibility!
  54. 54. Inventory set-up C inventory Bucket of Lego bricks B + D inventory house specs inventory Bucket of Lego bricks Bucket of Lego bricks + + house specs house specs A inventory E inventoryBucket of Lego bricks + Nothing. house specs
  55. 55. Be a QUALITY Do it Worker RIGHT Take PRIDE in the your Work first time!!Stay Motivated!
  56. 56. Iteration #3Lets play!
  57. 57. Go!
  58. 58. Stop!
  59. 59. Lets retrospect! what went well? what went wrong? how can we improve?
  60. 60. How many houses did we sell?Measuring Success
  61. 61. Jidoka intelligent automation Stop the production line, to build quality in!Quality Assurance
  62. 62. Jidoka to raise productivity ke -yofing on oka proo P ror a nd ErStop automatically if anything irregular occurs di ng oi Av ste Never produce defects wa Build it RIGHT the first time
  63. 63. andonQuality Assurance, in our world
  64. 64. simple tools to build quality in Go and See Analyse the situation One-piece flow & andon Ask 5 “Whys”Quality Assurance
  65. 65. Muda aka Waste 7 Wastes of Manufacturing Inventory Extra processing Overproduction Transportation Waiting Motion Defects - Shigeo ShingoMuda Toyota Production System
  66. 66. Muda aka Waste 7 Wastes of Manufacturing 7 Wastes of Software development Inventory Partially done work Extra processing Gold plating Overproduction Extra Features Transportation Task switching Waiting Waiting Motion Motion Defects Defects - Shigeo Shingo - Mary PoppendickMuda in our world Toyota Production System Lean Software Development
  67. 67. Thank you @ichsneha ichsneha.blogspot.inhttp://www.youtube.com/watch?feature=player_embedded&v=24PH9OCe4C8
  68. 68. The Lean Game Sneha Kadam @ichsneha ichsneha.blogspot.in

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