The document discusses the application of lean principles in various fields, particularly focusing on software development. It outlines an interactive agenda designed to simulate a production line experience, highlighting concepts such as push and pull systems, kanban, and waste reduction strategies. The aim is to improve efficiency and promote continuous improvement through practical hands-on activities.

1. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
The Lego Lean Game

2. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Agenda
• Quick introduction
• Simulating a production line
• How about software?
Hands
On
Results
Debriefing

3. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
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!

4. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Lean?
• Toyota Production System
– Revolutionized manufacturing (Ford vs.
Toyota)
– Started to be applied to different areas
• Google, Dell, Zara, …
• Product Development
• Supply Chain Management
• Health Care
• Software
• …

5. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Lean?

6. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
What we want to show
• Push and Pull Systems
• Kanban
• Systems Thinking
• Flow
• Heijunka
• Yatai (Work Cell)
• And more…

7. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Hands On – 1st Step
• Let’s simulate a production line…
• 4 Teams
• 4 rounds of 30 seconds
(x2)
• Follow the instructions
• Build houses
• 1 Piece = $ 1.00
• 1 House = $ 25.00
Task
1
Task
2
Task
3
Task
4
Sell
house

8. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Stay Motivated!

9. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Houston we have a problem…
What went wrong?

10. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Waste
• Visible
Inventory
• Over/Under
Production

11. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
7 Wastes of Manufacturing
• Overproduction
• Waiting
• Conveyance
• Overprocessing
• Inventory
• Motion
• Defects

12. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Push and Pull Systems
Expected
Demand
Mass
ProducCon
Economies
of
Scale
Customer
Requirements
On
Demand
ProducCon
AdaptaCon
• Push System – upstream information
• Pull System – downstream information

13. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Kanban
• Physical device
• Signals demand to downstream
processes
• Regulates demand on a pull system
• Limits Work in Process (WIP)
• Aids visual control
• Self-directing

14. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Kanban
Step
1
Task
1
Task
2
Step
2
Task
3
Step
3
Task
5
Task
5

15. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Kanban
Step
1
Task
1
Step
2
Task
3
Task
2
Step
3
Task
5
Task
5

16. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
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
• 4 rounds of 30 seconds (x2)
Task
1
Task
2
Task
3
Task
4
Sell
house

17. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Stay Motivated!

18. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Houston we have a problem…
What went wrong?

19. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Unleveled Process
• Another type of waste
• Some people working more than others
• Mura (Unevenness)
• Heijunka
Balance number of people based on
constraints

20. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Systems Thinking
• Why does it still feel wrong?
• What are the other teams
doing?
• What’s the purpose of the
system?
• Do we need 4 teams to
build a house?
• Teams 1 and 2 have
overlapping tasks

21. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Systems Thinking
• Why does it still feel wrong?
• What are the other teams
doing?
• What’s the purpose of the
system?
• Do we need 4 teams to
build a house?
• Teams 1 and 2 have
overlapping tasks

22. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Yatai (Work Cell)
• Multi-skilled worker
• Single piece flow

23. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Hands On – 3rd Step
• Using Work Cells
– Each group will build 4 houses
– Each person builds the whole house
– Signal when all houses are built
Build!
Sell
house

24. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Stay Motivated!

25. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Kaizen
• Continuous Improvement
• Reflect and adapt
• Learn by standardizing
• Long term thinking
• Respect People
Plan
Do
Check
Act

26. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Hands On – 4th Step
It’s your turn to help
us improve the
process?
?

27. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Stay Motivated!

28. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Our Results
Push
System
Kanban
Yatay
Team’s
Process

29. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Is That All?
• We saw some of the practices
• Practices are contextual
• Underlying principles must be understood
– Like agile!

30. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Is That All?
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
implementaCon
Focus
on
total
customer
saCsfacCon
A
system
for
producCon
floor
only
An
environment
of
teamwork
and
improvement
Implementable
in
a
short-­‐
or
mid-­‐
term
period
A
never
ending
search
for
a
beWer
way
Quality
built
in
process
EvoluConary

31. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Lean in Software Development
• Manufacturing is not the same as Software
Development
• Lean Product Development
– Knowledge flow is not the same as material
flow

32. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Lean in Software Development
• 7 Wastes in Software
– Extra Features
– Waiting
– Unnecessary Transportation
– Gold Plating
– Partially Completed Work
– Unnecessary Movement
– Defects
– Unused Employee Creativity

33. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Lean in Software Development
• Example: Push System in Software

34. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Lean in Software Development
• Example: Pull System in Software

35. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Lean in Software Development
• Example: Pull System in Software

36. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Lean in Software Development
• Much more:
– Eliminate Waste
– Create Knowledge
– Build Quality In
– Defer Commitment
– Deliver Fast
– Respect People
– Improve System

37. THIS MATERIAL MUST NOT BE USED FOR COMMERCIAL PURPOSES.
Thank you!
Questions?