LEAN LEGO GAME

Base on “KFI LEAN DEVELOPMENT” game on September 28th, 2010

Presented by Kry Herholdt & Arne Kolze – Teknologisk Institut with KFI Team
PURPOSE OF THE GAME

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
MATERIALS

- LEGO BLOCKS

2x4 = 100 PCS (RED)

2X4 = 200 PCS (BLUE)

2x2 = 100 PCS (YELLOW) 2x6 = 100 PCS (GREEN)

2X2 = 200 PCS (BLUE)

- JOLLY BOX 20X20X40 CM = 6 PCS

- CARTON BOX 8X8X16 CM = 40 PCS

- STOPWATCH = 3 PCS

- STEP COUNTER = 2 PCS

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 ASSEMBLY

1 PERSON AS QUALITY CONTROL
1 PERSON INTERNAL MATERIAL TRANSPORTER
1 PERSON EXTERNAL TRANSPORTER (DELIVERY TO CUSTOMER)
1 PERSON KEYMAN
1 PERSON SUPERVISOR
- OPERATORS AND QC ONLY COMMUNICATE WITH KEYMAN
IF 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 = 10000
FINISHED 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 CUSTOMER
STEPS 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 1
STOP PERFORMED ON LUNCH BREAK OR WHEN QUALITY ISSUES OCCURRED
LAYOUT
CUSTOMER

QC

OPERATOR 1
SUB ASSY BOTTOM

OPERATOR 2
SUB ASSY TOP
SUPERVISOR

OPERATOR 3
FULL ASSEMBLY

KEYMAN INTERNAL TRUCK

TRANSPORTATION
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
PRODUCTIVITY
312500
TURN OVER : PEOPLE
TRANSPORT STEP 4:18
DEFECT 218
DEFECT 53 (50%)
STAGE 2
- 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

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
PRODUCTIVITY
312500 375000
TURN OVER : PEOPLE
LEAD TIME 4:18 1:26
TRANSPORT STEP 218 1165
DEFECT 53 (50%) 48 (44%)
STAGE 3
- 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

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
PRODUCTIVITY
312500 375000 625000
TURN OVER : PEOPLE
LEAD TIME 4:18 1:26 0:53
TRANSPORT STEP 218 1165 144
DEFECT 53 (50%) 48 (44%) 0
STAGE 4
- 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)

OWNER IMPROVEMENT NOTES

- CHANGE BATCH SIZE IN TO 1 PC
- CHANGE LAYOUT WITH ONE PIECE FLOW LAYOUT
 ONE PIECE FLOW LAYOUT
TRANSPORT TO CUSTOMER
USE OUTSOURCING TRUCK
COST 50000 / DAY
DELIVERY : 1 BOX L & 1 BOX S (BALANCE) OPERATOR 2
PRODUCE LONG PRODUCT
CARTON BOX WITH 8 SEC TAKT TIME SUPERVISOR+ KEYMAN
FINISH GOODS ASSURE PRODUCTION SYSTEM FLOW
BATCH SIZE 3 SETS PREPARE CARTON BOX TO QC

SHORT GREEN 2X6 BLUE 2X2 YELLOW 2X2 BLUE 2X4

50PCS 50PCS 50PCS 50PCS
LONG
1L

QC
1S

RED 2X4 BLUE 2X2 YELLOW 2X2 BLUE 2X4

50PCS 50PCS 50PCS 50PCS

TAKT TIME
50 SETS / DAY
1 DAY = 8MINUTES = 480 SEC
480 / 50 = 9,6 SEC → TAKT 8 SEC (SAFETY)
WITH TIME COUNTER TAP THE QC EVERY 8 SEC OPERATOR 1
PRODUCE SHORT PRODUCT
WITH 8 SEC TAKT TIME

KANBAN
OPT 1 & 2 ONLY FILL WHEN KANBAN EMPTY
BATCH SIZE 1 L & 1 S
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 4
CHANGE 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 4950000
(after 6 min) (-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
PRODUCTIVITY
312500 375000 625000 1237500
TURN OVER : PEOPLE
LEAD TIME 4:18 1:26 0:53 0:24
TRANSPORT STEP 218 1165 144 0
DEFECT 53 (50%) 48 0 4
CONCLUSION
WITH 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