Teach Lean while Having Fun: The Use of Lean Simulation Games

Transcription

1 Continuous Improvement Professionals (CIP) Meeting at UTSA Teach Lean while Having Fun: The Use of Lean Simulation Games Hung-da Wan, Ph.D. Associate Professor and Assistant Chair of Mechanical Engineering Department University of Texas at San Antonio (UTSA) 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 1

2 Agenda What is simulation game? And why do we need them? What games can I find? The design aspects of simulation games Some useful tips 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 2

3 What is Lean Simulation Game? And Why? 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 3

4 Demo: A Game for Continuous Improvement Let s look at our Handout Passing process. Define the following items of the process : System: A Class = Teacher + Students + Classroom Objective: Passing handouts to every student quickly ( value added by the system) Problem: Takes more time than it should (opportunity for improvement) Performance Metrics: Identify improvement opportunities Solutions: Let s try again New Performance: Let s use the Best Practice from now on seconds seconds 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 4

5 Why use simulation games? Definitions of DMAIC Define the problem according to customer requirements. Measure defect rates and collect all relevant data. Analyze process data and determine the capability of the process. Improve the process and remove causes of defects. Control and mistake-proof the process to sustain the improvement. vs. Simulation Games 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 5

6 Benefits of Using Simulation Games An Active Learning Pedagogy Project-based learning Experienced-based learning Promotes Critical Thinking Relates theories to reality Reflect! Interactive, Competitive and Fun! Students said they vividly remember the game they played at the beginning of the semester and repeatedly referring back to what they learned in the game! 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 6

7 An Emphasis on Simulation Game playing is fun, but the purpose is to teach Lean concepts. Simulation is important! Demonstrate selected Lean concepts in a simplified setting. Make sure the participants can relate the activities to their work/life experience. Now, let s take a look at a popular 5S game. 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 7

8 Activity: The 5S Numbers Game The numbers represents application forms submitted to you for review and approval. Your job is to strike out the numbers from 1 to 49 in correct sequence (Sheet A). For example: We will have a 30 second shift to get as much done as possible Superteams, The 5S Numbers Game, ( 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 8

9 Lean Tool: 5S 5S A systematic way of creating a safe, efficient, and highly visible workspace for employees 整理 Seiri 整頓 Seiton 清掃 Seisou 清潔 Seiketsu 躾 Shitsuke = = = = = Sort Set in Order Shine Standardize Sustain 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 9

10 What Simulation Games can I find? 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 10

11 Types of Lean Simulation Games There are many types of simulation games. Game Environment Face-to-Face Computer based Game Setting Single Player, Simple Task Multi-player, Role-Playing in a System Single Player, Simple Task Multi-player, Role-Playing in a System Example 5S Number Game LEGO Airplane Assembly Flash-based 5S Game Web-based Office Game From literature review, we found more than 100 lean simulation games. 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 11

12 Example: LEGO Airplane Assembly Line Time: 90 minutes Participants: 6 Players per Group 4 Assembly Workstations 1 Quality Inspector 1 Teardown Station Scenarios: 4 Phases Phase I: Traditional Factory Phase II: Cellular Layout Phase III: One Piece Flow with Pull System Phase IV: Balanced Workload Product: Airplane made of LEGO 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 12

13 Example: PC-based Visual Aid Games 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 13

14 Which Game Should I Use? Beware! Not all games would work for you. LEGO Airplane Game needs 1.5 to 2 hours Web-based Game needs internet connection CAMLS s Lean Office Game requires 8 people in a team Choose the games based on your needs and constraints: Which lean concepts do you want to demonstrate? How much time do you have? How many people will participate? How many instructors would be needed? How much preparation efforts & cost? Simple is good! How confident are you to run this game? Easy is good! 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 14

15 The Design Aspects of Lean Simulation Games 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 15

16 What makes a good simulation games? These three aspects should be considered. Objectives & Constraints Dynamics of System Learning & Teaching Experience 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 16

17 Aspect #1: Objectives & Constraints Define These in Objectives: Define the lean concepts/tools to be demonstrated Performance metrics relevant to the selected lean concepts/tools Targeted group of learners Type of game to be developed/selected Identify These Constraints: Consider allotted time, space, budget, number of participants, number of facilitators, classroom size, equipment, and any other issues of feasibility. 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 17

18 Aspect #2: Dynamics of the System The game must demonstrate the impact of selected lean tools on relevant performance metrics within feasibility constraints. Desired Dynamics of the system: Before Lean: Confusion, frustration, visible wastes, opportunities of improvement. After Lean: Streamlined, easy to carry out, visible improvement in metrics. Other Properties: Fun to play, encourages critical thinking, sense of competition & achievement, etc. 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 18

19 Example of Desired Dynamics of System A Simulated System Capable of Demonstrating Pull Concept #1 #2 #3 #4 4 sec 8 sec 8 sec 16 sec Incorrect Designs #1 #2 #3 #4 10 sec 11 sec 11 sec 12 sec #1 #2 #3 #4 Before Pull : WIP increases by 3 in every 16 seconds ( WIP = (1/4 1/16)(60) = jobs/min). So, WIP reaches 22.5 jobs within 2 minutes. After Pull : WIP controlled at 4 jobs (no buffers) or 7 jobs (buffers between stations) while maintaining the same throughput. #1 #2 #3 #4 (a) Cycle Time Difference Not Significant Enough #1 #2 #3 #4 16 sec 8 sec 8 sec 4 sec #1 #2 #3 #4 (b) Bottleneck Position Located Incorrectly 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 19

20 Aspect #3: Learning & Teaching Experience Learning Experience Interesting and enjoyable. All participants should have a role. Allow participants to relate to realworld application and their daily job duties. Slight frustration in before phase makes after phase appreciated and memorable. The length: long enough to learn the concept but short enough to concentrate and feel engaged. The anxiety of competition and achievement helps with the learning experience. Teaching Experience Simple logistics in preparation, execution, and wrapping up, with reasonable amount of effort. Results should be predictable and manageable. No need to rely on instructor s memory, experience, or additional help from teaching assistants. When uncertainty is a factor (e.g., number of participants, available facility, etc.), games with higher flexibility and adaptability is preferred. 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 20

21 The 5S Game is successful, because Lean Concept: 5S. Relevant Metrics: Time to complete each task. Requirements & Constraints: Single player, simple tasks, flexible execution time. The game is free. Desired System Dynamics: With implementation of 5 S s, jobs can be completed quicker in each phase. Game Setting & Logistics: The scattered numbers can be easily related to office desks or inventory rooms. Preparation of the numbers sheets are very easy. 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 21

22 The LEGO game is successful, because Lean Concept: Cellular layout, one piece flow, pull system and Kanban, and workload balancing. Relevant Metrics: Throughput, total cycle time, defect rate, and WIP level. Requirements & Constraints: 1.5 to 2 hours of game time; 5 to 6 players per team; enough LEGO pieces. Desired System Dynamics: First phase creates frustration and low performance in all relevant metrics. With lean tools implemented in each phase, relevant metrics improves significantly. Results are predictable. Game Setting & Logistics: Assembly of LEGO airplane is simple and fun, and it can be relate to various systems of work flows. Once LEGO pieces are acquired, the game is easily reproduced. 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 22

23 Some Useful Tips for you Simulation games can be very effective teaching tools, when used correctly. Know what you need and what it takes. You can turn simple things into a game: Drawing, paper folding, dice rolling, math, spelling, ball catching, sticky notes, etc. Use Lean Concept while using the games. 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 23

24 Continuous Improvement Professionals (CIP) Meeting at UTSA Teach Lean while Having Fun: The Use of Lean Simulation Games Hung-da Wan, Ph.D. Associate Professor and Assistant Chair of Mechanical Engineering Department University of Texas at San Antonio (UTSA) 3/11/ CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 24