LEAN GAMES

Prepared by Vishnu Jayakumar

Game Names
5s study with an puzzle game
Time study & Lean Analysis of
Torch Factory Application
Time and Motion Study using Plug
Factory
5 S Puzzle Game
WHAT IS 5S ?

5S is a Japanese concept using
five simple steps to create a
conducive work atmosphere.

5S is a series of techniques that
provide the foundation for a visual
management system

5S - To create least waste way to
deliver value to the customers
5S IS A WAY OF
LIFE
JAPANESE TERMS ON 5S

SEIRI OR SORT

SEITON OR SET IN ORDER

SEISO OR SHINE

SEIKETSU OR STANDARDIZE

SHITSUKE OR SUSTAIN

WHAT IS 5S ?
5S
5S IS A WAY OF
LIFE
Level Sort Identify & eliminate what is not needed
1
2
3
4
5
Necessary and unnecessary items are mixed together in
the work area.
Necessary and unnecessary items are separated (excess
inventory, Obsolete tools & Equip)
All unnecessary items have been removed from the work
area.
Documented method to maintain work area free of
unnecessary items.
Waste is immediately visible and triggers a planned
response with root cause analysis and corrective action.
Sort
Levels of Achievement
5S IS A WAY OF
LIFE
Level
Set in Order A place for everything
and everything in its place
1
2
3
4
5
Documented method of visual sweep to identify items out
of place or exceeding quantity limits.
Defined process to evaluate and improve movement and
motion.
Tools, supplies and materials are randomly located.
Designated location established for all items as needed.
Designated locations are marked to make organization
more visible (color, outlines, labels, numbers, etc).

Set In Order
Levels of Achievement
5S IS A WAY OF
LIFE

Shine
Levels of Achievement
Level Shine An effective, organized environment
1
2
3
4
5
No visuals are in place. Work/break areas and machinery
are dirty and disorganized.
Visual display of data. Work/break areas and machinery
are cleaned on a regularly scheduled basis.
Visual controls are in place. Machines are cleaned daily.
Customers/suppliers are identified and value defined.
Real time metrics and visual management are in place.
Preventative maintenance is implemented.
Abnormal is immediately visible and triggers a planned
response with root cause analysis and corrective action.
5S IS A WAY OF
LIFE

Standardize
Levels of Achievement
Level Standardize Develop standards and stick to them
1
2
3
4
5
No attempt is being made to document or improve current
processes.
Current process is known, but not documented.
Current state is documented as Standard Work performed
the same by all employees.
Future state is documented. Implementation plan is
actively worked. Area metrics are linked to OpEx metrics.
Improvements are based on data and tracked for actual
results.
5S IS A WAY OF
LIFE

Sustain
Levels of Achievement
Level Sustain 5S is a way of life
1
2
3
4
5
Documented methods (Red Book) have been put into
place to ensure adherence to 5S.
Employees continually seek improvement opportunities.
Minimal attention is spent on 5S.
5S is a scheduled event.
5S practices are evaluated on a regular basis.
Procedure
Observe the items
Observe the Output in the figure
Keep the respective essential items near by
hand.
Make it with less utilization of time
Make sure the output is done correctly


Output
Time study & Lean
Assessment using
Torch Factory
Application
Basic Steps in Time Study
Select the work/method/operation/process to be
studied
Obtain and record the details about the
operations and the operator being studied
Breakdown the work into suitable elements
Measure the time for each element and hence
the time for the work cycle
Simultaneously rate the operator performance.

Activities in Torch Factory
Take the lower part of the torch.
Insert the batteries and the black ring.
Place the upper part in the floor.
Take the upper part and place the glass.
Insert the bulb holder and put the bulb.
Cover the bulb with the steel ring.
Put the cover for the bulb and complete the upper
part.
Insert the upper part with the lower part .
check for the working of the torch.
Time & Motion Study
Using Plug Factory
Procedure
Taking lower cap
Taking black cord grip and placing in slot
Taking screw 1 and putting in hole
Take Screw Driver
Fixing screw 1
Putting screw driver on the table
Taking Screw 2 and putting in hole
Taking screw driver again
Fixing screw 2
Putting screw driver on the table again
Taking blue pin and putting in slot



Talking brown pin(fuse Holder) and putting in
slot
Taking fuse holder and inserting in the slot
Taking fuse and fixing with the fuse holders
Taking the top covers and placing
Taking screw driver to fix the top cover
Screwing the top cover
Putting the screw driver on the table
Placing the assembled 3 pin plug in the tray