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Lean game air plane

Simple Lean game about flow, line balancing and Kaizen

Lean game air plane

  1. 1. Air Plane Game Exercise - Flow, Line balancing, Kaizen Inseong Kim
  2. 2. Game • Exercise objectives and purpose  Create the Standardized work and understand why the STD work is critical to Quality, Safety and productivity  Understand how we can link the STD work with operator balancing and Kaizen activities • What  Paper air plane game • Where  In the training room • How  4 rounds  See detailed roles on next page  Reflections by the teams • Results  KPIs evolution from round 1 to 4
  3. 3. Lay out and Preparations Work station 4 Work station 3 Work station 2 Work station 1 Team leader Material handler - A4 Paper - White, Yellow - Label – Buffer, Law material - Waste basket (Paper cup) - Scissors - Jigs, Raw material to make jigs - Stop watch - Scale (30 cm) - Marker pens - STD work document templates - Flip chart (Metrics print)  Lay out  Preparations Finished goods
  4. 4. Roles  1 Material handler : Trainer can be a material handler – Responsible to feed the line with raw material from the warehouse.  4 Operators – Responsible to assemble according to the assembly instruction on each station – Responsible to improve SQDC at own work station through Idea suggestion & Kaizen  1 Team leader / Supervisor – Responsible to observe any difficulties and problems at the assembly stations – Responsible to measure the cycle time by element each operator – Responsible to drive Kaizen activity to improve SQDC  1 PDI inspector : Trainer can be a material handler – Responsible for inspect any quality problems before delivering the finished goods to customer – Count the # of good parts and defected parts
  5. 5. Folding Process Job allocation -Round1 & Round2 •Operator 1 : ① •Operator 2 : ②~⑥ •Operator 3 : ⑦~⑩ •Operator 4 : ⑪~⑭ 1 2 3 4 5 678910 11 12 13 14
  6. 6. Timings Time Items Tasks 0:25 Game Introduction 0:10 Build Practice 0:10 Round 1 - Flow processing with Push -Create STD work -Measure the cycle time 0:20 Metrics & 1st Kaizen -Introduce pull 0:10 Round 2 - Flow processing with Pull 0:30 Metrics & 2nd Kaizen -Introduce operator balancing 0:15 Coffee 0:10 Round 3 - Flow processing with Pull & operator balancing 0:40 Metrics & 3rd Kaizen -Introduce/improve tools/jigs 0:10 Round 4 - Flow processing with Pull, operator balancing and improve tools/jigs 0:30 Metrics & Update STD work -Update STD work 0:30 Reflection by team Total productivity improvement 4:00 Tot End
  7. 7. Inspection specification • Good visual quality • Mismatch allowance : ± 2 mm • Cutting tolerance : ± 2 mm Width 15 mm ± 3 mm & Height 15 mm ± 3 mm 20 ± 3 mm
  8. 8. Metrics No Metrics Round 1 -Push Round 2 -Pull Round 3 -Balancing Round 4 -Tools/Jigs 1 Delivered Quantity (Total trucks delivered) 2 Good Parts (Total parts green OK) 3 % Green OK 4 Work In Process (Raw material +Buffer + SWIP) 5 Lead Time (Sec) 6 # of operators 4 4 4 4 7 Time (Min) 8 8 8 8 8 Productivity (Good parts/% of operator/Time)
  9. 9. Round 1 - Flow processing with Push Work station 4 Work station 3 Work station 2 Work station 1 Team leader Material handler Finished goods Law material Rule • Material handler - Feed the raw material (A4 paper-white) : 10 sheets for one delivery - Feed the yellow A4 paper in 3 minutes to measure manufacturing lead time • Operator - Continue to work if there are materials available - Possible to rest or play with smart phone if there are no WIPs • Inspector : Check/count defected parts & feedback to team leader/operators • Team leader - Measure cycle time and Create Standardized work - Evaluate team metrics results and communicate with operators • FIFO : All materials should be kept the FIFO rule between processes • 8 Min • Use Scissors & waste basket
  10. 10. Round 1 - Flow processing with Push  Push system : Supplier push the customer to accept their product  Inventory is unlimited  Inventory is increasing  Manufacturing lead time is too long  Big bottle neck operation  Other operator need to wait  Waiting = Waste  Unbalanced line between operators = Waste  Something is not right = Waste • Problems & Improvement opportunity
  11. 11. Round 2 - Flow processing with Pull Work station 4 Work station 3 Work station 2 Work station 1 Team leader Material handler Finished goods Buffer Buffer Buffer Mat’l Bin 1 Mat’l Bin 2 Rule • Material handler - Feed the raw material (A4 paper-white) with 2-bin concept - Feed the yellow A4 paper in 3 minutes to measure manufacturing lead time • Operator - Work only if there is no WIP in buffer - Possible to rest or play with smart phone if there are no WIPs • Inspector : Check/count defected parts & feedback to team leader/operators • Team leader - Evaluate team metrics results and communicate with operators • 8 Min • Use buffer label
  12. 12. Round 2 - Flow processing with Pull  Pull system : Customer pull the product from supplier when needed  More control of inventory  More organized work place • Improvements  But there is still lot to improve  The product does not met the demand. Now where is the problem?  The line is not balanced. - Operator 2 and 4 are doing a lot more work than others  But this time, the problem is because the line is not balanced. By balancing it, it can solve the problem! • Further Improvement opportunity
  13. 13. 0 5 10 15 20 25 30 1st Op 2nd Op 3rd Op 4th Op 1st Op 2nd Op 3rd Op 4th Op Operator Balance Chart / Yamazumi chart
  14. 14. Round 3 - Flow processing with Pull & Operator balancing Work station 4 Work station 3 Work station 2 Work station 1 Team leader Material handler Finished goods 8 Min Buffer Buffer Buffer Mat’l Bin 1 Mat’l Bin 2 Rule – Same as Round 2 • But the workload is properly balanced / divided to stabilize process with balancing • Material handler - Feed the raw material (A4 paper-white) with 2-bin concept - Feed the yellow A4 paper in 3 minutes to measure manufacturing lead time • Operator - Work only if there is no WIP in buffer - Possible to rest or play with smart phone if there are no WIPs • Inspector : Check/count defected parts & feedback to team leader/operators • Team leader - Evaluate team metrics results and communicate with operators
  15. 15. Round 3 - Flow processing with Pull & Operator balancing  Operator balancing - The workload is properly balanced and divided to stabilize process  Shorter lead time with “QRPS” problem solving • Improvements  But there is still lot to improve - need to improved the quality - need to reduce the cycle time • Further Improvement opportunity
  16. 16. Round 4 -Flow processing with Pull, operator balancing & tools/jigs Work station 4 Work station 3 Work station 2 Work station 1 Team leader Material handler Finished goods 8 Min Buffer Buffer Buffer Mat’l Bin 1 Mat’l Bin 2 Rule – Same as Round 3 • But new tools & jigs are used to improve quality & reduce cycle time • Material handler - Feed the raw material (A4 paper-white) with 2-bin concept - Feed the yellow A4 paper in 3 minutes to measure manufacturing lead time • Operator - Work only if there is no WIP in buffer - Possible to rest or play with smart phone if there are no WIPs • Inspector : Check/count defected parts & feedback to team leader/operators • Team leader - Evaluate team metrics results and communicate with operators
  17. 17. Operator Balance Chart 0 5 10 15 20 25 30 1st Op 2nd Op 3rd Op 4th Op 1st Op 2nd Op 3rd Op 4th Op
  18. 18. Jigs Reference • Half folding jigs • Wing folding jigs • Cutting jigs…
  19. 19. Metrics No Metrics Round 1 -Push Round 2 -Pull Round 3 -Balancing Round 4 -Tools/Jigs 1 Delivered Quantity (Total trucks delivered) 10 12 14 15 2 Good Parts (Total parts green OK) 7 9 11 15 3 % Green OK 70% 75% 79% 100% 4 Work In Process (Raw material +Buffer + SWIP) 57 9 9 9 5 Lead Time (Sec) 75 65 62 56 6 # of operators 4 4 4 4 7 Time (Sec) 8 8 8 8 8 Productivity (Good parts/% of operator/Time)

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