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The Lego Lean Game (XP 2009 version)
The document summarizes a workshop on introducing Lean concepts using a simulation game called "The Lego Lean Game". The workshop covers Lean principles like push/pull systems, Kanban, flow, and continuous improvement. Participants role-play building houses on an assembly line to experience problems with batched production and long lead times. They then apply Kanban and other Lean tools to smooth workflow. The document emphasizes that Lean is not just a set of tools but a management philosophy for eliminating waste and respecting people.
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Editor's Notes
- #9 35 min
- #11 Lean came with definition of waste Everything that is done but not necessary for the final productThere is one visible kind of waste now: inventory How may houses produced x 25 Pieces x 1Compare inventory accumulation with chartShow over/under production in the example Houses produced but not sold Houses demanded but not produced
- #12 Overproductionproducing items when orders have not been received.Waiting People waiting to have their setup readyConveyance Unnecessary transportationOverprocessing More work than necessary Inventory Example cited beforeMotion Time lost in moving parts of the system/productDefects If in the end we have a defect in the product, everything was thrown awayIt could be argued that the work done is going to be useful in the future But how about if the market changes?
- #13 PushFord: demand was not an issue. Sell everything that is produced. Goal: maximize productionEver cheaper labour, ever faster machines ran out of both
- #14 TaiichiOhno went to the US to study the cars industry, and said that wanted an industry that worked like an american supermarket
- #15 PullSupermarketProduce based on demandNeed a way to signalize when more work has to be done
- #16 You need somehow to signalize that more work is needed
- #21 55 minExplain how the process should work
- #23 Break after retrospective
- #24 One solution: balance number of people based on constraints
- #25 Video: Production line of BoingBalance people based on constraintWhat’s the ideal scenario?
- #32 1:55
- #35 Discussao sobre como modificar o processo
- #37 2:30
- #39 On a practice level Pull system/Kanban (Later section)On a principle level Challenging status quo Inspect quality in Competing against yourself Empowering people
- #41 Predictable and Repeatable (as in Manufacturing): Build process / Deployment processCreative / Information Flow / Create Knowledge (as in Product Development)