Lego Exercise Part II
Lean State
Grow &
Innovate
Eliminate Reduce
Waste Variability
© 2003 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 1
Module Objectives
• Re-connect to Lego exercise Part 1
• Recap week 1 tools and methodology
• Application of Lean Concepts
- Show future state
- Show single piece flow
© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 2
Lean Principles
1) Specify value in the eyes of the customer
2) Identify the value stream and eliminate waste
3) Make value flow at the pull of the customer
4) Involve and empower employees
5) Continuously improve in pursuit of perfection
Flow Principles Look Ideal State:
at the Entire • Only Value Added
Process Steps/time
• Balanced flow
• No Scrap/Rework
• No Back Flows
• No Stoppages
Pack
Receiving Machining Assembly
and Ship • Continuous Flow
© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 3
Using the Value Stream Mapping Tool
Focus on a specific product or part
Product/Process family to value stream
Family
Understanding how the process
currently operates. Learning to see the
Current State Map waste is the foundation for the future
state
Designing a Future State using
lean and variation reduction
Future State Map tools on the CSM to create flow
and eliminate waste
Develop 30/60/90 day
Implementatio Implementation Plan then
n Plan repeat the process
© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 4
Standard Work
• Best, easiest, safest way you know today.
• Simple and conspicuous
• Documentation of know-how with input from
operations, quality, and engineering
• Consistent with quality, delivery, cost requirements
• Employees need not only be aware a standard exists,
but understand it and follow it! One standard at a
time.
• Results in balanced production with minimum
inventory and labor
• Focuses Management
• It is the basis for training
• It is the basis for audit and diagnosis
• Control variability
• Ensures sharing of “Best Practices”
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Standard Work
Workstation: Engine Assy Method Sheet #2
Model – Red Car
2
1
Assemble (1) ea. head cover to top of each engine
block.
1a 3 3a
X 45 45
1b
2
Assemble (2) ea. Engine blocks to
the 4-peg base leaving 2 of the Note: Flare
base pegs uncovered. Engine Finished Assembly
heads must tilt outward. Engine Heads
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Lean Simulation
Lean State Multimedia Projector and Flip
Chart
Computer
Training
Kit
Simulation Supplies
= Work In
Process
Kanban
= 2 Bin
Withdraw Rear Drive
Kanbans Train Assembly
= Method Sheet Forward
Chassis to
Rear Drive
train
Spoiler
Final
Assembly
Assembly
Engine
Assembly
© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 7
Textron Mixed Model Build Sequence
Build Order # Model Type
1 Red Car
2 Blue Car
3 Red Car - no spoiler
4 Blue Car
5 Red Car
6 Blue Car - no spoiler
7 Red Car
8 Blue Car
9 Red Car
10 Blue Car
11 Red Car
12 Blue Car - no spoiler
13 Red Car
14 Blue Car
Blue Car
Spoiler -
Spoiler -
15 Red Car - no spoiler
Red Car
16 Blue Car
17
18
Red CarNo
Blue Car
19 Red Car
No
20 Blue Car - no spoiler
21 Red Car
22 Blue Car
23 Red Car - no spoiler
24 Blue Car
25 Red Car
26 Blue Car
27 Red Car
28 Blue Car - no spoiler
29 Red Car
30 Blue Car
31 Red Car - no spoiler
32 Blue Car
33 Red Car
34 Blue Car
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2 Bin Withdraw Kanban Card
Part Number:
The part number and 330-9 Spoiler Mount
name in this bin
Quantity/bin:
12
How many parts to put
in the bin
Where the parts User location:
Spoiler Assy Station
are used
Supply location:
Materials Stockroom
Where the parts are
#5 stocked
Number of bins:
How many bins 2
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Work In Process Kanban
Engine Kanban
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Simulation Roles – Phase 2
1. Director of Operations
2. Stock Clerk 1
3. Expeditor 1
4. Forward Chassis
5. Rear Drive Train
6. Engine Build Up
7. Spoiler Assembly
8. Final Assembly
9. Time Keeper/WIP Data collector
10. Other Data gathering as directed by
the instructor
Instructor Picks Director of Operations, Director
of Operation Picks Team
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Run Lean Simulation
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Lego Simulation
Observations
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Clean up
• Everyone needs to help take the Legos apart and
return parts to stock room
• Remember not to take apart models
• After everything is put away it is time to take a break
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Lessons Learned/Pitfalls to Avoid
• Encourage Improvement
- Widespread orientation to CI, quality, training and
recruiting workers with appropriate skills
- Create common understanding of need to change to
lean
• Employee Involvement
- Push decision making to the appropriate team
member (Operator, support function, etc.)
- Trained and truly empowered people
• Share information and manage expectations
• Identify & empower champions, particularly
operation managers
- Remove roadblocks (i.e., people, layout, systems)
- Make it both directive yet empowering
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Lessons Learned/Pitfalls to Avoid
• Atmosphere of Experimentation
- Work in a small groups (pilot) & expand with success
- Willingness to take risks (Safety nets)
• Installing “enlightened” and realistic performance
measures, evaluation, and reward systems
- Realign performance goals to meet new objectives
- Do measure results and not the number of
activities/events
- Tie improvements, long term, to key macro level
performance targets. (i.e. inventory turns, quality,
delivery, overall cost reductions).
• The need to execute pilot projects prior to rolling
culture out across organization is also essential
(e.g., model lines, kaizen blitzes)
- After early wins in operations, extend across ENTIRE
organization
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Hints for Success
• Unyielding Leadership
• Benchmark outside successes and failures
• Define goals and objectives
• Start with pilot area (i.e., constraint operation, strong
commitment, easier deployment, considerable waste or
variation, process closest to customer, confined area, etc.)
• Form a team & improve communication
• Assess process & identify “Low Hanging Fruit (LHF)
Projects”
• Determine baseline to monitor improvements
• Develop a project timeline (include due dates & owners)
and begin with LHF projects
• Implement changes, monitor & adjust
• Continue improving area or target new processes
• Consider improving business or engineering processes
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Key Learning Points
•
•
•
•
•
•
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Module Objectives Revisited
• Re-connect to Lego exercise Part I
• Recap week 1 tools and methodology
• Application of Lean Concepts
- Show future state
- Show single piece flow
© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 19
Configuration Management
Revision Date Author Description of Change
5.0 1/2005 Jeff Green Block Change Rewrite
© 2005 Textron Inc. Lego Simulation Part 2 V5.0 [1/2005] 20
