LeanLegoGameSlidesLong PDF

The Lean Lego Game
Danilo Sato, Francisco Trindade

XP 2009 – Sardinia - Italy
25th May 2009
© ThoughtWorks 2008
Agenda
•! Quick introduction
•! Simulating a production line
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•! How about software? ()%*+,%&
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!
Lean?
•! 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?
What we want to show
•! Push and Pull Systems
•! Kanban
•! Systems Thinking
•! Flow
•! Heijunka
•! Yatai (Work Cell)
•! And more…
Hands On – 1st Step
•! Let’s simulate a production line…
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•! 4 Teams •! Follow the instructions

•! 4 rounds of 40 seconds •! Build houses
•! 1 Piece = $ 1.00
•! 1 House = $ 25.00
Stay Motivated!
Houston we have a problem…
What went wrong?
Waste
•! Visible Inventory
•! Over/Under Production
7 Wastes of Manufacturing
•! Overproduction
•! Waiting
•! Unnecessary Transportation
•! Overprocessing
•! Inventory
•! Motion
•! Defects
Push and Pull Systems
•! Push System – upstream information
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•! Pull System – downstream information
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Kanban
•! Physical device
•! Signals demand to downstream processes
•! Regulates demand on a pull system
•! Limits Work in Process (WIP)
•! Aids visual control
•! Self-directing
Kanban
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Kanban
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Kanban
Kanban
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Kanban
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Hands On – 2nd Step
•! Using Pull and Kanban
–! Setup minimum buffers at intermediate steps
–! Demand comes first
–! Items are produced to fill gaps in the buffers
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•! 4 rounds of 40 seconds
Stay Motivated!
What went wrong?
Unleveled Process
•! Another type of waste
•! Some people working more than others
•! Mura (Unevenness)
•! Heijunka
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
Systems Thinking
•! Why does it still feel wrong?
•! What are the other teams
doing?
•! What’s the purpose of the
system?
Systems Thinking
•! Why does it still feel wrong?
•! What are the other teams
doing?
•! What’s the purpose of the
system?
Let’s Experiment
•! Do we need 4 teams to build a house?
•! Teams 1 and 2 have overlapping tasks
Yatai (Work Cell)
•! Multi-skilled worker
•! Single piece flow
Hands On – 3rd Step
•! Using Work Cells
–! Each person builds a house
–! Round of 160 seconds
–! Signal (raise your hand) if you finish your house
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Stay Motivated!
What went wrong?
Kaizen
•! Continuous Improvement
•! Reflect and adapt B+"#& -;&
•! Learn by standardizing
•! Long term thinking G?,& E:)?4&
•! Respect People
Kaizen
•! Continuous Improvement
•! Reflect and adapt B+"#& -;&
•! Learn by standardizing
•! Long term thinking G?,& E:)?4&
•! Respect People
Improving the Process
It’s your turn to help

N& us improve the
N& process
Hands On – 4th Step
•! Discuss your own
process
3)"@& 3)"@& •! 1 round for each
5& 6& team
3)"@& 3)"@&
7& 8&
Stay Motivated!
Our Results
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Is That All?
•! We saw some of the practices
•! Practices are contextual
•! Underlying principles must be understood
–! Like agile!
What is Lean?
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Lean in Software Development
•! Manufacturing is not the same as Software
Development
•! Lean Product Development
–! Knowledge flow is not the same as material flow
•! Extra Features (Overproduction)
•! Waiting (Waiting)
•! Unnecessary Transportation (Unnecessary Transportation)
•! Gold Plating (Overprocessing)
•! Partially Completed Work (Inventory)
•! Unnecessary Movement (Motion)
•! Defects (Defects)
•! Unused Employee Creativity
•! Example: Push System in Software
•! Example: Pull System in Software
•! Example: Pull System in Software
Kanban
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Kanban
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•! Much more: •! Lean:
–! Eliminate Waste –! Genchi Gembutsu
–! Create Knowledge –! A3
–! Build Quality In –! 5 Whys?
–! Defer Commitment –! Stop the Line
–! Deliver Fast –! Andon
–! Respect People –! Jidoka
–! Improve System –! Mistake Proofing
Thank you!
Questions?
dsato@thoughtworks.com dtsato.com
ftrindad@thoughtworks.com franktrindade.com

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The Lean Lego Game

Danilo Sato, Francisco Trindade

25th May 2009

•! How about software? ()%*+,%&

We’re here to introduce you to Lean

3"%4&5& 3"%4&6& 3"%4&7& 3"%4&8& 9)++&:;*%)&

•! 4 Teams •! Follow the instructions

What went wrong?

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<=>)?,)$& A"%%& <?;#;@0)%&

<=>)?,)$& A"%%& <?;#;@0)%&

•! Pull System – downstream information

9)++&:;*%)& 3"%4&8& 3"%4&7& 3"%4&6& 3"%4&5&

What went wrong?

What went wrong?

It’s your turn to help

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H#& ()"$O&D;/& ()"$O&D;/& ()"$O&D;/&

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