The Lego Lean Game. Danilo Sato, Francisco Trindade XP 2009 Sardinia - Italy. 25 th May 2009

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1 The Lego Lean Game Danilo Sato, Francisco Trindade XP 2009 Sardinia - Italy 25 th May 2009

2 Agenda! Quick introduction! Simulating a production line!"#$%&'#& -)./0)1#2&! How about software? ()%*+,%&

3 Why are we here?! Lean concepts starting to be noticed in the software world! But not everyone has had contact with Lean principles and practices We re here to introduce you to Lean Hands On!

4 ! Toyota Production System! Revolutionized manufacturing (Ford vs. Toyota)! Started to be applied to different areas! Google, Dell, Zara,! Product Development! Supply Chain Management! Software! Healthcare! Lean?

5 Lean?

6 What we want to show! Push and Pull Systems! Kanban! Systems Thinking! Flow! Heijunka! Yatai (Work Cell)! And more

7 Hands On 1 st Step! Let s simulate a production line 3"%4&5& 3"%4&6& 3"%4&7& 3"%4&8& 9)++&:;*%)&! 4 Teams! 4 rounds of 40 seconds! Follow the instructions! Build houses! 1 Piece = $ 1.00! 1 House = $ 25.00

8 Stay Motivated!

9 Houston we have a problem What went wrong?

10 ! Visible Inventory! Over/Under Production Waste

11 7 Wastes of Manufacturing! Overproduction! Waiting! Unnecessary Transportation! Overprocessing! Inventory! Motion! Defects

12 Push and Pull Systems! Push System upstream information <=>)?,)$& A"%%& B/;$*?C;#& ;D&9?"+)&

13 Push and Pull Systems! Push System upstream information <=>)?,)$& A"%%& B/;$*?C;#& ;D&9?"+)&

14 Push and Pull Systems! Push System upstream information <=>)?,)$& A"%%& B/;$*?C;#& ;D&9?"+)&! Pull System downstream information G$">,"C;#& B/;$*?C;#&

,)$& -)@"#$& A"%%& B/;$*?C;#& <?;#;@0)%& ;D&9?"+)&!

15 Kanban! Physical device! Signals demand to downstream processes! Regulates demand on a pull system! Limits Work in Process (WIP)! Aids visual control! Self-directing

16 Kanban B/;?)%%&G& H$+)& I*J)/& K*++& B/;?)%%&I& L;/40#2&

17 Kanban B/;?)%%&G& H$+)& I*J)/& B/;?)%%&I& L;/40#2& Kanban

18 Kanban B/;?)%%&G& L;/40#2& I*J)/& B/;?)%%&I& L;/40#2&

19 Kanban B/;?)%%&G& H$+)& I*J)/& K*++& B/;?)%%&I& L;/40#2&

20 ! Using Pull and Kanban Hands On 2 nd Step! Setup minimum buffers at intermediate steps! Demand comes first! Items are produced to fill gaps in the buffers 9)++&:;*%)& 3"%4&8& 3"%4&7& 3"%4&6& 3"%4&5&! 4 rounds of 40 seconds

21 Stay Motivated!

22 Houston we have a problem What went wrong?

23 Unleveled Process! Another type of waste! Some people working more than others! Mura (Unevenness)! Heijunka

24 Flow! Final goal is a leveled process! Production line must be a continuous flow! One piece is bought when one piece is delivered! Sustainable pace

25 Systems Thinking! Why does it still feel wrong?! What are the other teams doing?! What s the purpose of the system?

26 Systems Thinking! Why does it still feel wrong?! What are the other teams doing?! What s the purpose of the system?

27 Let s Experiment! Do we need 4 teams to build a house?! Teams 1 and 2 have overlapping tasks

28 ! Multi-skilled worker! Single piece flow Yatai (Work Cell)

29 ! Using Work Cells Hands On 3 rd Step! Each person builds a house! Round of 160 seconds! Signal (raise your hand) if you finish your house 9)++&:;*%)& I*0+$M&

30 Stay Motivated!

31 Houston we have a problem What went wrong?

32 Kaizen! Continuous Improvement! Reflect and adapt! Learn by standardizing! Long term thinking! Respect People B+"#& G?,& -;& E:)?4&

33 Kaizen! Continuous Improvement! Reflect and adapt! Learn by standardizing! Long term thinking! Respect People B+"#& G?,& -;& E:)?4&

34 Improving the Process N& N& It s your turn to help us improve the process

35 Hands On 4 th Step 3)"@& 5& 3)"@& 6&! Discuss your own process! 1 round for each team 3)"@& 7& 3)"@& 8&

36 Stay Motivated!

37 Our Results P"#."#& Q","0&

38 ! We saw some of the practices! Practices are contextual! Underlying principles must be understood! Like agile! Is That All?

39 What is Lean?!"#$% &$'#%()*%+,%-.#% G&,"#20.+)&/)?0>)&D;/&%*??)%%% /0'12#"% &$'#%()*%+,% G&?;#%0%,)#,&S"O&;D&,:0#40#2% G&#)V)/&)#$0#2&%)"/?:&D;/&"&.)X)/& S"O% Y*"+0,O&.*0+,&0#&>/;?)%%% <V;+*C;#"/O%

40 Lean in Software Development! Manufacturing is not the same as Software Development! Lean Product Development! Knowledge flow is not the same as material flow

41 Lean in Software Development! Extra Features! Waiting! Unnecessary Transportation! Gold Plating! Partially Completed Work! Unnecessary Movement! Defects! Unused Employee Creativity (Overproduction) (Waiting) (Unnecessary Transportation) (Overprocessing) (Inventory) (Motion) (Defects)

42 Lean in Software Development! Example: Push System in Software

43 Lean in Software Development! Example: Pull System in Software

44 Lean in Software Development! Example: Pull System in Software

45 Kanban 3;&-;& H#& G#"+O%0%& ()"$O&D;/& -)V& H#&-)V& ()"$O&D;/& 3)%,& H#&3)%,& ()"$O&D;/& 9:;S?"%)& -;#)&

46 Kanban 3;&-;& H#& G#"+O%0%& ()"$O&D;/& -)V& H#&-)V& ()"$O&D;/& 3)%,& H#&3)%,& ()"$O&D;/& 9:;S?"%)& -;#)&

47 Lean in Software Development! Much more:! Eliminate Waste! Create Knowledge! Build Quality In! Defer Commitment! Deliver Fast! Respect People! Improve System! Lean:! Genchi Gembutsu! A3! 5 Whys?! Stop the Line! Andon! Jidoka! Mistake Proofing

48 Thank you! Questions? dtsato.com franktrindade.com

Appendix Lean Glossary Page 1

Appendix Lean Glossary Page 1 Andon Board A visual control device in a work area giving the current status on performance to expectations and alerting team members to emerging issues. Batch-and- Queue