Profero, Inc. Leaders in Lean Enterprise. The Training Game Exchange

Transcription

1 Leaders in Lean Enterprise The Training Game Exchange Session D3 Monday, March 8, :30 pm 4: 30 pm Learning Outcomes Learn new training tools. Network with other trainers. Get ideas on how to create training exercises for your organization. Please fill out the feedback forms for each training game Profero, inc

2 Learning Games 5S 5S Numbers Game Visual Hide & Seek Batch Size Reduction Index Card Exercise Continuous Improvement & Flow Tennis Ball Exercise Others Let s Go! This session is geared for the trainer A lot to cover in a short time we ll move pretty fast and might not cover the entire exercise We ll cover the background and items needed Think of this as guidelines, adapt it to your needs. There is a lot of flexibility with these exercises. Have FUN!!! Profero, inc

3 Leaders in Lean Enterprise The 5S Numbers Game A fun and exciting way to present the 5S concepts to your team! Credits This exercise is based on an exercise from which was adapted from one created by Kirt Tassmer of Stanley Fastening Systems. The original game was developed by RWD Technologies, Ltd.D Disclaimer This is for entertainment purposes only. 5S Supply is not liable for any unintended outcomes. Background This is a simple training game you can use to show how to perform 5S and to drive home important key points Number of participants: any Time: 30 minutes Profero, inc

4 Items Forms Overall Score and Rounds 1-5 for each participant Timer Pens or pencils for each participant PowerPoint (optional) Agenda Before State Round 1 Sort Round 2 Set-in-Order Round 3 Shine Standardize Sustain Round 4 Benefits Round 5 Profero, inc

5 Instructions Round 1 Please wait until you hear the entire instructions before starting DO NOT turn over the page until asked to do so Individually, with a pen or pencil locate and strike out the numbers 1 through 50 in sequential order (1, 2, 3, 4, 5 ) You will have 30 seconds to complete this task Leaders in Lean Enterprise GO! Profero, inc

6 Report Out Round 1 Record your highest number found and a comment on your Overall Scorecard sheet The instructor will ask for your score the lowest score is what s recorded for the entire group What was it like trying to do this? How did it feel? How can we apply this to everyday life? Leaders in Lean Enterprise Were there any quality issues? the 6 51 and which one is the 9? Is this an 8, 88, 4, 84??? Which one is Is this 66 or 48 99? 89 or 68? Why 64is listed 100 twice? Profero, inc

7 Sort To sort through, to sort out Guideline: If it is not needed in the next 30 days, Red Tag it When in doubt, move it out! 5S Red Tag Technique Place a Red Tag on the item and move it to the 5S Red Tag Holding Area Items will be dispositioned: keep, throw out, donate, scrap, shred, recycle, etc Leaders in Lean Enterprise Let s red tag the 14 numbers we don t need (51-100) and the duplicate Profero, inc

8 Leaders in Lean Enterprise Leaders in Lean Enterprise Now let s move them 14 65to the S Red Tag Holding Area Profero, inc

9 Leaders in Lean Enterprise Leaders in Lean Enterprise Profero, inc

10 Instructions Round 2 Let s do the same exercise with the unneeded items removed from the work area - with a pen or pencil locate and strike out the numbers 1 through 50 in sequential order (1, 2, 3, 4, 5 ) You will have 30 seconds to complete this task Leaders in Lean Enterprise GO! Profero, inc

11 Report Out Round 2 Record your highest number found and a comment on your Overall Scorecard sheet The lowest score is what s recorded for the entire group What was the exercise like this time? What can we learn from this? Set-in-Order Now that the area has been cleared out of unnecessary items, it is time to find a home for items that will remain Guideline: Any item that you want to keep after the 5S Red Tagging Event needs to have a specific home A place for everything and everything in its place. Organize items to make them convenient to get and put away Use visual controls to help this process (signs, lines, labels, color-coding) Profero, inc

12 Leaders in Lean Enterprise Let s rearrange the 14 numbers 17 in order that we will 24use 25 them Leaders in Lean Enterprise Profero, inc

13 1 2 Leaders in Lean Enterprise Leaders in Lean Enterprise Did you notice that we had to work around a few things like the numbers that were already there? Profero, inc

14 Instructions Round 3 Let s do the same exercise with the numbers better organized - with a pen or pencil locate and strike out the numbers 1 through 50 in sequential order (1, 2, 3, 4, 5 ) You will have 30 seconds to complete this task 1 2 Leaders in Lean Enterprise GO! Profero, inc

15 Report Out Round 3 Record your highest number found and a comment on your Overall Scorecard sheet The lowest score is what s recorded for the entire group What was the exercise like this time? What benefits can you see from Sort and Set-in-Order? Record on Scorecard sheet Shine Now that the area has been cleared out of unnecessary items, it is time to shine the items that remain Guideline: Get items to a like-new condition Clean and inspect or inspect through cleaning Everyone participates, make it simple and easy to get cleaning supplies and schedule it! If you find something out that may become an issue, fix it or have it fixed Profero, inc

16 Leaders in Lean Enterprise For Shine we will make sure the numbers are in good working order. So let s clean this mess 17up! Leaders in Lean Enterprise Profero, inc

17 Standardize We need to have standards for the first three S s: Sort, Set-in-Order and Shine Guideline: Make up the rules for the first three S s and then follow and enforce them. Make up the rules and then follow them Don t forget to consider companywide policies like color-coding, signage, replenishment, etc Make the rules easy to follow 1 Leaders in Lean Enterprise After looking at all the styles of font and sizes the team determined that some of these items can be standardized Profero, inc

18 Leaders in Lean Enterprise Leaders in Lean Enterprise Let s add some more visuals like color-coding and lines Profero, inc

19 Leaders in Lean Enterprise Sustain Now that you have a well organized, clean and safe work environment, we must keep it that way Guideline: It s not something extra, it s part of everyday work Make 5S part of everyday life. Sustain helps build the discipline we need to have a great Lean organization Profero, inc

20 Instructions Round 4 In order to Sustain our gains we must be able to recognize abnormal conditions Let s do a quick 5S Audit of the area Circle any defects that you find You will have 30 seconds to complete this task Leaders in Lean Enterprise GO! Profero, inc

21 Report Out Round 4 How many did you find? The 2 is missing 9 is upside down 11 and 12 are mixed up 16 is not completely in it s home 24 and 34 are in the wrong location is missing 46 is askew How did you know? Leaders in Lean Enterprise Profero, inc

22 Instructions Round 5 Let s do the same exercise after applying our 5S principles - with a pen or pencil strike out the numbers 1 through 50 in sequential order (1, 2, 3, 4, 5 ) You will have 30 seconds to complete this task Leaders in Lean Enterprise GO! Profero, inc

23 Report Out Round 5 Record your highest number found and a comment on your Overall Scorecard sheet The lowest score is what s recorded for the entire group What was the exercise like this time? What benefits can you see from Sort and Set-in-Order? How can we apply this to everyday life? Before & After State Before Excess materials Excessive search time Large area Cluttered Difficult After The correct materials Minimal search time Smaller area Clean, neat & organized Easy Profero, inc

24 29 23 Before Leaders in Lean Enterprise After Leaders in Lean Enterprise Profero, inc

25 Benefits of 5S What benefits did we realize by applying 5S to our simulated workplace? Quality Cost Delivery/Service Quantitative Qualitative Resource This game is available at : PowerPoint Forms Video Profero, inc

26 Leaders in Lean Enterprise Hide & Seek Hurry we need this now! Background Use this exercise to show the power of visual controls Two versions manufacturing & office Number of participants: 4-5 people per team, 2-4 teams Time: minutes Profero, inc

27 Items Small objects (like K nex pieces) for manufacturing File folders for office Timer Flipchart to record scores Colored markers, post-it notes, paper, tape, etc to make signs How to Round 1 Have one person from each team act as the new employee Bring them out to the hallway and show them the item need to find Let them know that their team is not going to help them Have them wait in the hall until they are called-in Profero, inc

28 How to Round 1 While the new employees wait in the hall, explain to the teams that they need to hide the object somewhere in the room Don t make it obvious and don t make it impossible Have one person from each team act as the timer the time from when their employee walks in the room until that person finds the correct object That can t help they can only say things like Hurry, We need this now!!! Encourage the team to badger the new employee GO! How to Round 1 Profero, inc

29 Report Out Round 1 How did you feel? What was it like? Round 1 Round 2 Team 1 Team 2 Team 3 How to Round 2 Have the new employees go out into the hallway again Explain to them that they will do the same thing as before try to find the item as fast as they can. Let them know it will be a few minutes, so relax Profero, inc

30 How to Round 2 Have the team hide the objects again, they choose even a harder spot this time This time the teams can make whatever visuals they would like (signs, lines, labels, color-coding, etc.) to make it easier for their employee Coach them on good visuals (size, locations, think of the user, etc.) Same as before time and no helping only badgering GO! How to Round 2 Profero, inc

31 Report Out Round 2 How did you feel this time? What was it like? Round 1 Round 2 Team 1 Team 2 Team 3 Leaders in Lean Enterprise Index Card Game Batch size reduction really works! Profero, inc

32 Background Use this exercise to show how batch size reduction reduces lead-time Number of participants: 4-5 people per team, 2-3 teams Works best if the teams are sitting next to each other Variation: Signatures or use stickers, scissors, tape, etc. Time: minutes Items Colored index cards (3 x 5 ) cards per team, 4 colors x 10 cards Timer Pens or pencils for each participant Optional: stickers, scissors, tape, stamps Profero, inc

33 How to Prior to the exercise sort out the index cards 10 of each color x 4 colors for a total of cards per team Based on the number of teams have: 1 team do the exercise in batches of 10 1 team in batches of 5 1 team in batches of 1 How to Explain to each person that all they have to do is clearly print their first and last name on the card When they have completed their batch (10, 5, or 1) they can move that batch to the next person Make sure they understand that they can t move it on until the batch is complete Profero, inc

34 How to Once everyone understands the game, start the clock Act as a mean supervisor or manager and tell the teams to Go faster! and Hurry Record the time each team finishes. Report Out Which team finished first and why? What was it like? Batch Size Time Team 1 Team 2 Team Profero, inc

35 Leaders in Lean Enterprise Tennis Ball Exercise Continuous improvement and flow Background Use this exercise to show how teams can work on continuous improvement and flow Number of participants: 4-8 per team Time: 30 minutes Profero, inc

36 Items Two Tennis ball cans per team one with three tennis balls the other one empty Timer Post-it notes Performed in four rounds How to Round 1 Prior to the exercise, number post-it notes around the table based on the number of people participating Make sure that the first one is located by you in the front of the room Have all the other post-its out of order Tell the team that you are the manager Demonstrate to the team the how to exactly perform this process and say All three balls have pass through both hands from one canister to the other. Profero, inc

37 How to Round 1 Tell the to start at #1 and move both cans to the next number until they are finished and then deliver the cans to you Time the entire process Act like a mean manager hover over them. Tell them to hurry and don t let them do it their own way. Correct them if they try to do it a different way than what you showed them. Report Out Round 1 Ask them what it was like? Round Time Profero, inc

38 How to Round 2 Tell the team that it wasn t fast enough. Your boss is getting on your back about how slow it is. This time have them do it exactly the same except way but really hurry this time! Really bug them by telling them to Hurry, go faster! and Come on, do better! If there is a quality issue (like they drop the tennis balls or the cans) tell them that you are not happy because you have to write up a corrective action report now. How to Round 3 Tell the team that it still wasn t fast enough and they have to do better By this time the team really wants to make changes Tell them they need to cut the last time in half Let them work on solutions, but it has to be approved by you first Only let them change the order of the numbers (to sequential around the room) You ll probably hear complaints that you don t let them make changes they want to make. Just tell them that you have heard this all before. Profero, inc

39 How to Round 4 Usually by now the time is lower Tell the team that you have a friend that his company does the same thing as you and they can do it in 1second! Challenge the team to come up with any solution that can match that They will probably say it can t be done or can we do it the way we want to How to Round 4 Just remind them that they can t violate the policy of All three balls have pass through both hands from one canister to the other. Teams have come up with some pretty unique solutions You can let the team practice before you take the offical time Profero, inc. 2010

40 Report out - Round 4 Let them talk about what changed form round 1 to 4 How the manager has to let the team come up with ideas How a simple thing like flow improves the time How they go over the That s impossible stage Round 1 newly trained Round 2 boss yelling at them to just go faster Round 3 limited changes Round 4 Amazing breakthrough Leaders in Lean Enterprise Wrap-up Comments, questions and evaluations Profero, inc. 2010

41 Comments - Questions What did you think? Ideas for improvements Think how you apply this to your organization I ll stick around to answer any questions Hopefully you found this educational and entertaining! Wrap-up Can we apply this to the real world? Share an Ah-ha something you learned, something that s new, something that s different or something that made an impression on you Profero, inc

42 Host Anthony Manos Tony Manos is a Professional Business Advisor with expertise in Lean. Trained and certified by the Department of Commerce, National Institute of Standards and Technology (NIST) in Lean principles and as a trainer in Lean courses. He is an international trainer and speaker on Lean topics. Mr. Manos is a Senior Member of ASQ, SME and AME and is a Shingo Prize examiner Feel free to contact me if you have any comments or questions Tony Manos Catalyst, Suite #18 USA Cell: Fax: anthony.manos@proferoinc.com Website: Additional Resources Group 5S Supply Profero, inc

43 Leaders in Lean Enterprise Thank you Have fun! Profero, inc