Process Management

The Boat Exercise

The purpose of this exercise is to illustrate how managers can select different
processes to perform the same task. You do not need any prior knowledge or skills
to perform this exercise.
Your team has to produce paper boats that are sold in stacks of four. The
following six steps are to be followed to make each boat.
________________________________________________________________________________
Start Output of Step 1: First Fold and Write
Serial Number

________________________________________________________________________________

Output of Step 2: Second Fold Output of Step 3: Third Fold

________________________________________________________________________________
Output of Step 4: Attach Clips Output of Step 5: Finish

Process
Managem
ent is fun

________________________________________________________________________________
Output of Step 6: Inspect and Pack

Count into stacks of four boats and secure each stack with a paper clip on the
bottom of the boats. Make sure that the folds are smooth and parallel to the edges,
the paper clips are vertical and hidden and the logo is centered as shown in the
diagram.
___________________________________________________________________________________
You will have to perform this task following the process described to you by
the instructor. Your aim is to minimize inventory and provide quality boats to the
customer in a timely manner. Happy sailing. \_,__/
 Boat Exercise Data Sheet

Collect data for boats numbered 4 and 8. You should not stop
working at the 8th boat but keep making boats until signaled to
stop.

Process I

Boat # Start Time1 Finish Time**2 Flow Time =

Finish Time –
Start Time
4
8

Average Flow
Time

Work-in-Process Inventory: ________

Finished Goods Inventory (# of stacks for 4 boats): ____________

Process II
Boat # Start Time Finish Time Flow Time =
Finish Time –
Start Time
4
8

Average Flow
Time

Work-in-Process Inventory: ________

Finished Goods Inventory (# of stacks for 4 boats): ____________

Changes Made:
1.

2.

1
Start Time is the time when the paper is taken from the pad for folding.
2
Finish Time is the time when the boat is packed in a batch of four.
3.