LEAN LEGO GAME

Base on “KFI LEAN DEVELOPMENT” game on September 28th, 2010Presented by Kry Herholdt & Arne Kolze – Teknologisk Institut with KFI Team

TO OPEN EYES AND MINDS OF PEOPLE ABOUT LEAN AND ONE-PIECE FLOW PRODUCTION,BENEFITS AND EFFECTIVENESS THAT CAN BE OBTAINED FOR COMPANY AND EMPLOYEES

PURPOSE OF THE GAME

MATERIALS

- LEGO BLOCKS

- JOLLY BOX 20X20X40 CM = 6 PCS

- CARTON BOX 8X8X16 CM = 40 PCS

- STOPWATCH = 3 PCS

- STEP COUNTER = 2 PCS

2x4 = 100 PCS (RED)2X4 = 200 PCS (BLUE)

2x2 = 100 PCS (YELLOW)2X2 = 200 PCS (BLUE)

2x6 = 100 PCS (GREEN)

RULES OF THE GAME

- ALL PARTICIPANTS EMPLOYED IN KFI LEAN DEVELOPMENT- TWO MODELS ARE MANUFACTURED (BOTTOM PART SAME, DIFFERENT TOP)

- GAME WILL HAVE 4 STAGE REPRESENT 4 WORKING DAY- ONE DAY = 8 HOURS → 8 MINUTES- 50 PCS OF EACH MODEL SOLD PER DAY (PER GAME), CUSTOMER EXPECTS A STEADY DELIVERY DURING THE DAY

- COMPANY EMPLOYS 8 PEOPLE- FACTORY AREA IS ESTIMATED TO 20X20 M2- JOBS :

1 PERSON AS OPERATOR SUB ASSY PROCESS BOTTOM PARTS

1 PERSON AS OPERATOR SUB ASSY PROCESS TOP PARTS (SHORT & LONG)

1 PERSON AS OPERATOR FULL ASSEMBLY1 PERSON AS QUALITY CONTROL1 PERSON INTERNAL MATERIAL TRANSPORTER1 PERSON EXTERNAL TRANSPORTER (DELIVERY TO CUSTOMER)1 PERSON KEYMAN1 PERSON SUPERVISOR

- OPERATORS AND QC ONLY COMMUNICATE WITH KEYMANIF NEEDS TRANSPORTER THEY SHOUT TO KEYMAN “KEYMAN.. TRANSPORT FROM... TO...”

- ONLY TRANSPORTER AND SUPERVISOR CAN MOVE- MATERIAL TRANSPORTER ONLY MOVE AS KEYMAN ORDER- MATERIAL TRANSPORTER CAN ONLY CARRY 1 FULL CARTON BOX (1 BATCH) & 5 EMPTY BOX- EVERY STEPS OF MATERIAL TRANSPORTER COUNT WITH STEP COUNTER- ONLY QC CAN SEE DEFECTS / REJECT, IF QC FINDS DEFECT IT'S REPORTED TO SUPERVISOR- SUPERVISOR MUST SOLVE QUALITY ISSUES , STOP THE LINE IF NEEDED AND TELL THE PROBLEM TO THE SECTION THAT PRODUCE DEFECT- PAYMENT FOR DELIVERY = 50000 PER FINISHED CORRECT PRODUCT- WIP VALUE

SEMI FINISHED PRODUCT = 10000FINISHED PRODUCT = 25000

- PRODUCTIVITY MEASURED = TURN OVER DEVIDED BY NUMBER OF PEOPLE- EACH STAGE (8 MINUTES) FINISHED COMPANY WILL MEASURE

FINISHED DELIVERED PRODUCTS AND WIP PRODUCTION LEAD TIME FROM START PRODUCTION TO DELIVERY AT CUSTOMERSTEPS PERFORMED BY MATERIAL TRANSPORTER

COMPANY REPORT PER STAGE

STAGE 1

- CUSTOMER DEMAND 50 LONG & 50 SHORT- LAYOUT BY PROCESS, DETERMINED BY OWNER- PRODUCE AS MUCH AS POSSIBLE- DURATION 8 MINUTES- BATCH SIZE 10 PCS- 1 BATCH = 1 CARTON BOX

AFTER GENERAL RULES EXPLAINED AND ROLES WERE ASSIGNED “START” STAGE 1STOP PERFORMED ON LUNCH BREAK OR WHEN QUALITY ISSUES OCCURRED

LAYOUT

QC

OPERATOR 1SUB ASSY BOTTOM

OPERATOR 2SUB ASSY TOP

OPERATOR 3FULL ASSEMBLY

KEYMAN INTERNALTRANSPORTATION

TRUCK

SUPERVISOR

CUSTOMER

RESULT OF STAGE 1- EVALUATION AFTER THE END OF STAGE ONE

FROM THE GAME HELD ON SEPTEMBER 28TH, 2010 WE HAVE :

KFI LEAN DEVELOPMENT DAY 1 DAY 2 DAY 3 DAY 4

BATCH SIZE 10

PEOPLE 8

AREA 20 m2

SOLD 50S / 50L

DELIVERED NUMBER 30S / 20L

TURN OVER (@ 50 000) 2500000

WIP SEMI FINISH (10 000) 62

WIP FULL FINISH (25 000) 10

VALUE OF WORK IN PROCESS 870000

PRODUCTIVITYTURN OVER : PEOPLE

312500

TRANSPORT STEP 4:18

DEFECT 218

DEFECT 53 (50%)

- AFTER STAGE 1 OWNER COLLECT ALL EMPLOYEE TO SHOW THEM THE RESULT- BRAIN STORMING AND DIG IDEA FROM ALL PARTICIPANTS TO GET IMPROVEMENT- A FEW OF CHANGES DISCUSSED (ADD PEOPLE, QC EACH PROCESS, COMBINED PROCESS, CHANGE BATCH SIZE, CHANGE LAYOUT)- COMPANY CANNOT AFFORD TO CHANGE LAYOUT BECAUSE MONEY TIED UP IN WIP AND DEFECTS

STAGE 2

AFTER IMPROVEMENT PLAN APPROVED AND AGREED “START” STAGE 2

- REDUCE BATCH SIZE IN TO 3 PCS- STILL SAME LAYOUT- SAME PEOPLE IN SAME POSITIONS- DURATION 8 MINUTES- QUALITY ISSUES FROM WRONG MATERIAL SUPPLY

RESULT OF STAGE 2- EVALUATION AFTER THE END OF STAGE TWO

FROM THE GAME HELD ON SEPTEMBER 28TH, 2010 WE HAVE :

KFI LEAN DEVELOPMENT DAY 1 DAY 2 DAY 3 DAY 4

BATCH SIZE 10 3

PEOPLE 8 8

AREA 20 m2 20 m2

SOLD 50S / 50L 50S / 50L

DELIVERED NUMBER 30S / 20L 36S / 24L

TURN OVER (@ 50 000) 2500000 3000000

WIP SEMI FINISH (10 000) 62 78

WIP FULL FINISH (25 000) 10 18

VALUE OF WORK IN PROCESS 870000 1230000

PRODUCTIVITYTURN OVER : PEOPLE

312500 375000

LEAD TIME 4:18 1:26

TRANSPORT STEP 218 1165

DEFECT 53 (50%) 48 (44%)

- AGAIN AFTER STAGE 2 OWNER COLLECT ALL EMPLOYEE TO SHOW THEM THE RESULT- NOW OWNER ALLOW EVERYTHING FOR IMPROVEMENT INCLUDE RE-LAYOUT- GIVEN 10 MINUTES TO DISCUSS AND DO THE IMPROVEMENT (RE-LAYOUT)- AFTER THAT THEY MUST EXPLAIN WHAT IMPROVEMENT TAKEN

STAGE 3

AND THEN “START” STAGE 3

- CHANGE BATCH SIZE IN TO 5 PCS- LAYOUT DECIDE AFTER DISCUSSION- SAME PEOPLE IN SAME POSITIONS- DURATION 8 MINUTES

RESULT OF STAGE 3- EVALUATION AFTER THE END OF STAGE THREE

FROM THE GAME HELD ON SEPTEMBER 28TH, 2010 WE HAVE :

KFI LEAN DEVELOPMENT DAY 1 DAY 2 DAY 3 DAY 4

BATCH SIZE 10 3 5

PEOPLE 8 8 8

AREA 20 m2 20 m2 20 m2

SOLD 50S / 50L 50S / 50L 50S / 50L

DELIVERED NUMBER 30S / 20L 36S / 24L 50S / 50L

TURN OVER (@ 50 000) 2500000 3000000 5000000(after 6 min)

WIP SEMI FINISH (10 000) 62 78 68

WIP FULL FINISH (25 000) 10 18 25

VALUE OF WORK IN PROCESS 870000 1230000 1305000

PRODUCTIVITYTURN OVER : PEOPLE 312500 375000 625000

LEAD TIME 4:18 1:26 0:53

TRANSPORT STEP 218 1165 144

DEFECT 53 (50%) 48 (44%) 0

- AGAIN AFTER STAGE 3 OWNER COLLECT ALL EMPLOYEE TO SHOW THEM THE RESULT- TURNOVER INCREASE AFTER IMPROVEMENT- PRODUCTIVITY INCREASE- BUT STILL WE HAVE PROBLEM WITH A LOT OF WIP- PRODUCE MORE THAN CUSTOMER DEMAND (FINISH AFTER 6 MINUTES)- NOW OWNER WILL DECIDE EVERYTHING- LET PARTICIPANTS TAKE REST WHILE OWNER DO CHANGES (SET UP ONE PIECE FLOW SYSTEM)

STAGE 4

OWNER IMPROVEMENT NOTES

- CHANGE BATCH SIZE IN TO 1 PC- CHANGE LAYOUT WITH ONE PIECE FLOW LAYOUT

ONE PIECE FLOW LAYOUT

QC

OPERATOR 1PRODUCE SHORT PRODUCT WITH 8 SEC TAKT TIME

OPERATOR 2PRODUCE LONG PRODUCTWITH 8 SEC TAKT TIME SUPERVISOR+ KEYMAN

ASSURE PRODUCTION SYSTEM FLOWPREPARE CARTON BOX TO QC

SHORT

LONG

CARTON BOXFINISH GOODSBATCH SIZE 3 SETS

1L

1S

KANBANOPT 1 & 2 ONLY FILL WHEN KANBAN EMPTYBATCH SIZE 1 L & 1 S

BLUE 2X450PCS

YELLOW 2X250PCS

BLUE 2X250PCS

RED 2X450PCS

BLUE 2X450PCS

YELLOW 2X250PCS

BLUE 2X250PCS

GREEN 2X650PCS

TRANSPORT TO CUSTOMERUSE OUTSOURCING TRUCKCOST 50000 / DAYDELIVERY : 1 BOX L & 1 BOX S (BALANCE)

TAKT TIME50 SETS / DAY1 DAY = 8MINUTES = 480 SEC480 / 50 = 9,6 SEC → TAKT 8 SEC (SAFETY)WITH TIME COUNTER TAP THE QC EVERY 8 SEC

ONE PIECE FLOW RULE

- QC JOB : CHECK PRODUCT QUALITY AND PUT IN TO THE BOX(1 BATCH =3 SETS LONG & 3 SETS SHORT)

- QC ONLY DO THE JOB IF TAPPED BY TIME COUNTER EVERY 8 SECOND- QC TAKE PRODUCTS ONLY ABOVE KANBAN- QC MUST BALANCE THE OUTPUT PRODUCT (LONG & SHORT)- IF KANBAN EMPTY OPERATOR 1 & 2 MUST FILL IT- IF THERE IS STILL A PRODUCT ABOVE KANBAN, OPERATOR CANNOT FILL IT JUST HOLD UNTIL QC TAKE THE PRODUCT- SUPERVISOR TAKE CARTON BOX IF FULL (3 SETS EACH BOX)TO DELIVERY TERMINAL, AND REPLACE WITH EMPTY BOX- QC ASK SUPERVISOR TO STOP THE LINE IF FIND ANY DEFECT

AFTER ONE PIECE FLOW RULES EXPLAINED AND ROLES WERE ASSIGNED “START” STAGE 4CHANGE THE OPERATOR IN THE MIDDLE OF THE GAME

RESULT OF STAGE 4- EVALUATION AFTER THE END OF STAGE FOUR

FROM THE GAME HELD ON SEPTEMBER 28TH, 2010 WE HAVE :

KFI LEAN DEVELOPMENT DAY 1 DAY 2 DAY 3 DAY 4

BATCH SIZE 10 3 5 1

PEOPLE 8 8 8 4

AREA 20 m2 20 m2 20 m2 8 m2

SOLD 50S / 50L 50S / 50L 50S / 50L 50S / 50L

DELIVERED NUMBER 30S / 20L 36S / 24L 50S / 50L 50S / 50L

TURN OVER (@ 50 000) 2500000 3000000 5000000(after 6 min)

4950000(-50000 truck)

WIP SEMI FINISH (10 000) 62 78 68 8

WIP FULL FINISH (25 000) 10 18 25 2

VALUE OF WORK IN PROCESS 870000 1230000 1305000 130000

PRODUCTIVITYTURN OVER : PEOPLE 312500 375000 625000 1237500

LEAD TIME 4:18 1:26 0:53 0:24

TRANSPORT STEP 218 1165 144 0

DEFECT 53 (50%) 48 0 4

CONCLUSIONWITH ONE PIECE FLOW SYSTEM :- PRODUCTIVITY INCREASE- REDUCE MANHOUR- REDUCE SPACE NEEDED FOR PRODUCTION- PRODUCTION CAPACITY COMPATIBLE WITH CUSTOMER DEMAND- PRODUCTION MORE FLEXIBLE FROM ANY INTERFERENCE- BRING PROBLEM TO SURFACE (DEFECT QUICKLY FOUND AND SOLVE)- REDUCE WASTE OF TRANSPORTATION- KANBAN CONTROL AMMOUNT OF WORK IN PROCESS (WIP CONCEALING PROBLEMS)- IMPROVE VALUE ADDED ACTIVITY- REDUCE NON VALUE ADDED ACTIVITY- RESPONSIVE WITH MARKET DEMAND (FASTER LEAD TIME)- COMPANY BECOME MORE COMPETITIVE- COMPANY GET PROFIT AND EMPLOYEE'S WORK SAFE AND GET THE BONUSES