Lean Simulation Game Why Creep when We Can Fly?
Content 1. Objectives of the Lean simulation game.. 3 2. Rules. 4 3. KPI s..... 5 4. Program.... 6
1. Objectives of the Game Primary Purpose: - Provide an overview of Lean techniques. - Introduce Lean Thinking At the end of the game the participants will: - Have a basic understanding of the lean tools and techniques and their application; - Recognize the benefits of the Lean manufacturing system; - Increase their engagement towards achievement of long term company excellence through lean practices; - Understand the path to application of pull flow systems and Kan-Ban Benefits: - The Lean Simulation Why Creep when We Can Fly? is a very powerful tool for learning the advantages of the lean methodology by playing a practical game. - It is very easy to understand the lean tools. - It is interesting to be played by the managers in order for them to be self-convinced in the benefits of the methodology. - It can be played also by the operators in order to change their attitude towards the new way of thinking Lean Thinking.
2. Rules In this manufacturing simulation, you are to assume the role of production team building various colored widgets for your customer. The object of the game is to best satisfy your customer with the lowest possible cost. There are three main production processes in the simulation: Base Assembly Product Assembly Heat Treat There are also 2 additional processes: Inspection Warehouse Your production team is composed of the following positions: 1. Customer 2. Truck Driver 3. Warehouse Manager 4. Inspector 5. Heat Treat Operator 6. Assembly Operator 7. Base Assembly Operator 8. Machine Set-Up Technician 9. Master Scheduler 10. Buyer 11. Supplier 12. Tool Crib Supervisor 13. Process Improvement Engineer 14. Plant Manager 15. Material Handler
3. KPI s The Lean simulation game is conducted in 4 rounds. At the end of each round the following KPI s are measured and analyzed: Customer Service Rate (%): Total Units Produced: (pcs.) Average Cycle Time (s.): Total WIP ( ): Total Finished Goods ( ): Total Overhead ( ): Total Units Sold ( ): Quality rate (%): Total Cost ( ): Cost per Unit ( ): PROFIT ( ): Based on the result the team will make improvements in the process after each round. The final goal is the implementation of the Lean principles and obtaining the effects with improved achievements of the KPI s
4. Program Duration 10:00-10:15 10:15-10:30 10:30-10:50 10:50-11:20 11:20-12:00 12:00-12:40 Lunch break Day One Content Opening of the workshop. Presenting the consultants and the participants. Expectations from workshop. Introduction to the Lean thinking. World class manufacturing. History. What is lean? Principles in the Lean thinking. Part one - value and wastes. Practical examples from Bulgarian and foreign companies. Film about the wastes in the Lean thinking. Types of wastes. Discussion. Principles in the Lean thinking. Part two. Value stream. Flow. Pull. Continuous improvement. 12:40-12:55 Thinking "Out of the box". Introduction to Just in Time Production. 12:55-13:25 Aims. Main tools. Cycle time and Tact time. Value Stream Mapping (VSM). 13:25-14:05 Description. Main Symbols. Current state. Lead time and Value added time. Future state. Example from the bulgarian Industry. Discussion. 14:05-14:20 Coffee break 14:20-14:50 14:50-15:20 15:20-16:20 16:20-17:00 Just in Time Production. Part one. Flow in the production lines. Layout. Cellular layout. Inventory reduction. Role or the operators. Simulation game. Just in Time Production. Part two. Flow between production lines. Pull vs. push. Leveling. Kanban. Just in Time Production in bulgarian companies. Practical examples. Discussion. Day Two Duration Content 10:00-10:20 Summary Lean principles, wastes, tools in Just in Time Production. 10:20-12:00 Pull Flow Simulation game - part one. 12:00-12:40 Lunch break 12:40-15:30 Pull Flow Simulation game - part two. Conclusion. 15:30-16:00 Feedback from each participant. Discussion of possible ways to implement the Lean principles.