Lean Lego Game Slides Short

The Lean Lego Game
Francisco Trindade
Danilo Sato
Wednesday, 2 September 2009
Agenda
Quick Introduction
Simulating a production line
How about software ?
Debriefing
Hands On
Results
Process
3x
Lean concepts
being used in the
software world
But without much contact
with Lean principles and
practices
Why ?
... over the years there have been some

ostensibly !lean" promoters that reduced lean
thinking to a mechanistic superficial level of
management tools such as kanban and queue
management.
... the essence of successful lean thinking is
building people, then building products and a
culture of challenge the status quo
continuous improvement Lean Primer (http://tinyurl.com/owvhut)
Were here to introduce you to Lean

Lean
Revolutionized
manufacturing
Applied to
different areas
Flow
Pull
Push
Yatai
Systems Thinking
Heijunka
What we want to show

Task 1
Task 2
Task 3
Task 4
4 Teams
Follow the instructions
Build houses
4
Rounds
1 Piece = $ 1.00
1 House = $ 25.00 30 secs
Hands on - 1st Step
What went wrong ?
Houston, we have a problem...

Visible Inventory
Over/Under Production
Waste
Visible Inventory
Over/Under Production
700
Task 4
Task 3
Task 2
Task 1
525
350
175
0
Waste
Overproduction
Inventory
Waiting
Motion
Overprocessing
Defects
Unnecessary
Transportation
7 Wastes of Manufacturing
Push
Expected
Demand
Mass
Production
Economies
of Scale
Push and Pull Systems

Push
Any colour, as
long as its black
Henry Ford

Push
Expected
Demand
Mass
Production
Economies
of Scale
Pull
Adaptation
On Demand
Production
Customer
Requirements

Pull

TASK 2
TASK 1
Kanban
TASK 2
TASK 1
Kanban
TASK 2
TASK 1
Kanban
Signals demand
Regulates demand
Limits Work in Process
Aids visual control
Self-directing
Signals demand
Regulates demand
Limits Work in Process
Aids visual control
Self-directing
Kanban
Task 1
Task 2
Task 3
Task 4
4 Teams
Pull System
4 Rounds
30 secs
Hands on - 2nd Step

Task 1
Task 2
Task 3
Task 4
Pull System
Setup minimum buffers at intermediate steps
Demand comes first
n
a
b
n
Ka
Items are produced to fill gaps in the buffers
Hands on - 2nd Step

What went wrong ?

Another type of waste

Some people working more than others
Mura (Unevenness)
Heijunka
Unleveled Process
Goal is a leveled process

Production line must be a continuous flow
One piece is bought when one piece is delivered
Sustainable pace
Flow
unners
r
e
th
t
o
n
,
n
to
a
b
Watch the
url.com/owvhut)
rimer (http://tiny
Lean P
Goal is a leveled process

Production line must be a continuous flow
One piece is bought when one piece is delivered
Sustainable pace
Flow
http://www.youtube.com/watch?v=nq9SnHXIG00
unners
r
e
th
t
o
n
,
n
to
a
b
Watch the
url.com/owvhut)
rimer (http://tiny
Lean P
Why does it still feel wrong?

What are the other teams doing?
ad system
b
A
Whats the purpose of the system?

will beat a
good person
every time
W. Eduards Deming
Systems Thinking
Do we need 4 teams to build a house?

Teams 1 and 2 have overlapping tasks
Systems Thinking
Multi-skilled worker
Single piece flow
Yatai (Work Cell)

Sell house
Build
Hands on - 3rd Step

Sell house
Build
Each person builds a house

Round of 120 seconds
Signal if you finish it
Hands on - 3rd Step

What went wrong ?

Continuous Improvement
Reflect and adapt
Learn by standardizing
Long term thinking
Respect People
to
ty
ili
b
a
s
it
s
a
w
e
g
ta
n
a
v
Toyotas real ad
s
e
e
y
lo
p
m
e
ry
a
in
rd
o
f
o
t
c
lle
harness the inte
Kaizen
Gary Hamel
Push System
Pull System
Yatai
Whats next ?
Is that all ?
Push System
We saw some of the practices
Pull System
Practices are contextual

Principles must be understood
Yatai
Is that all ?
What TPS is Not

recipe for success
A consistent
way of thinking
management
project
or program
A total
management
philosophy
A set ofontools
implementation
Focus
total for
customer
satisfaction
A system
for production
floor only
An
environment
of teamwork
and improvement
A
never ending in
search
for or
a better
wayperiod
Implementable
a shortmid- term
What is Lean ?
X
Lean in Software Development
Overproduction
Inventory
Waiting
Motion
Overprocessing
Defects
Unnecessary Transportation

Overproduction
Waiting
Overprocessing
Inventory
Motion
Defects

Overproduction
Extra Features
Waiting
Gold Plating
Overprocessing
Partially Completed Work
Inventory
Motion
Defects
Unused Employee Creativity

Kanban Board

Kanban Board

Controlling Kanban
Do you have a stable process ?

Controlling Kanban

Controlling Kanban

Controlling Kanban

Much more:
Eliminate Waste
Create Knowledge
Build Quality In
Defer Commitment
Deliver Fast
Respect People
Improve System
Genchi Genbutsu
A3
5 Whys?
Stop the Line
Andon
Jidoka
Mistake Proofing

X
Agile Open Office

http://connect.thoughtworks.com/agile2009/
TW One on One
http://connect.thoughtworks.com/1on1
Something extra...
Thank You!
Questions ?
dsato@thoughtworks.com
ftrindad@thoughtworks.com
dtsato.com
franktrindade.com
@dtsato
@frankmt

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The Lean Lego Game

Wednesday, 2 September 2009

Wednesday, 2 September 2009

... over the years there have been some

Were here to introduce you to Lean

What we want to show

Wednesday, 2 September 2009

What went wrong ?

Houston, we have a problem...

Push and Pull Systems

Push and Pull Systems

Push and Pull Systems

Push and Pull Systems

Wednesday, 2 September 2009

Wednesday, 2 September 2009

Wednesday, 2 September 2009

Hands on - 2nd Step

Hands on - 2nd Step

Wednesday, 2 September 2009

What went wrong ?

Houston, we have a problem...

Another type of waste

Goal is a leveled process

Wednesday, 2 September 2009

Goal is a leveled process

Wednesday, 2 September 2009

Why does it still feel wrong?

Whats the purpose of the system?

Do we need 4 teams to build a house?

Yatai (Work Cell)

Hands on - 3rd Step

Each person builds a house

Hands on - 3rd Step

Wednesday, 2 September 2009

What went wrong ?

Houston, we have a problem...

Practices are contextual

What TPS is Not

Lean in Software Development

Lean in Software Development

Lean in Software Development

Lean in Software Development

Lean in Software Development

Do you have a stable process ?

Lean in Software Development

Lean in Software Development

Lean in Software Development

Lean in Software Development

Lean in Software Development

Agile Open Office

Wednesday, 2 September 2009

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