This document describes a lean simulation activity where participants simulate the workflow of tokens through different departments. Workers flip tokens and pass them to the right while managers time their departments and the CEO times the overall workflow. The simulation is done with different batch sizes to optimize the workflow and identify any tradeoffs between department and overall efficiency. Systems thinking concepts like vanity metrics are discussed to emphasize optimizing the overall system rather than just individual parts.

1. Lean Simulation
Mark Shead
mark.shead@xeric.net

3. = position that needs to have a stop watch (cell phone, etc.)

4. = position that needs to have a stop watch (cell phone, etc.)
Tokens need to all be
same side up

5. Departments

6. Work Simulation:
Each department flips over
tokens and passes to the right

7. Managers

8. Managers record the
total work time of their
department.

10. Managers need to
inspire their department
to work quickly

11. (can’t touch the tokens)

12. CEO

13. CEO records the
cumulative work time
of all departments.

14. CEO records all timings
on the flip board.

15. Workers

16. Workers flip tokens and
then pass them to the
right.

17. The only people who
can flip the tokens

18. Left Hand
Flip Tokens

19. Right Hand
Pass Tokens

20. Flip Pass

21. You aren’t allowed to physically
mess with people at other tables.

22. 20 tokens
Department 1
Department 2
Department 3
Department 4
Overall Time
(CEO)

23. Left hand starts to flip all tokens over
Start timer
Start timer

24. Left hand flips each token over

25. Right hand passes all tokens to right

26. Last token passed Starts flipping tokens
Stop timer Start timer

27. Left hand flips each token

28. Right hand passes all tokens to right

29. Last token passed Starts flipping tokens
Stop timer Start timer

30. Left hand flips each token

31. Right hand passes all tokens to right

32. Last token passed Starts flipping
Stop timer Start timer

33. Left hand flips last token
Stop timer
Stop timer

34. 20 tokens
Department 1 20 seconds
Department 2 24 seconds
Department 3 19 seconds
Department 4 18 seconds
Overall Time
(CEO)
72 seconds

35. Flip each token
over with left
hand

36. Then use right
hand to pass the
tokens to
the right

37. Ready

38. Set

39. Go

40. 20 tokens
Department 1 20 seconds
Department 2 24 seconds
Department 3 19 seconds
Department 4 18 seconds
Overall Time
(CEO)
72 seconds

41. 10 Token Batches

42. Left hand starts to flip 10 tokens
Start timer
Start timer

43. Left hand flips 10 tokens

44. Right hand passes the 10 tokens to right

45. Continue flipping Starts flipping tokens
Start timer

46. Pass last 10 tokens Continue
Stop timer

47. Ready

48. Set

49. Go

50. 20 tokens 10 tokens
Department 1 20 seconds XX seconds
Department 2 24 seconds XX seconds
Department 3 19 seconds XX seconds
Department 4 18 seconds XX seconds
Overall Time
(CEO)
72 seconds XX seconds

51. Workers - Did you feel sufficiently
inspired by your managers?

52. 5 Token Batches

53. Ready

54. Set

55. Go

56. 20 tokens 10 tokens 5 tokens
Department 1 20 seconds XX seconds XX seconds
Department 2 24 seconds XX seconds XX seconds
Department 3 19 seconds XX seconds XX seconds
Department 4 18 seconds XX seconds XX seconds
Overall Time
(CEO)
72 seconds XX seconds XX seconds

57. Best department time?

58. Best overall time?

59. Why?

60. Smaller Batch Sizes

61. Optimized for Flow

62. What happens if you optimize
for the department time?

65. Systems Thinking

66. Vanity Metrics

67. You can get better numbers in
an area without getting better
overall outcomes.

68. What seems most beneficial at one
level, may be detrimental to the
system as a whole.

69. If you would like to do this
simulation back home…

71. Please reach out…

72. Links & Contact
• http://www.youtube.com/markshead
• https://blogs.harvard.edu/markshead/
• https://www.linkedin.com/in/markshead
• Twitter @MarkWShead
• Email: mark.shead@xeric.net