Lean Lego Game SOP

(1)

LEAN LEGO GAME

(2)

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

(3)

MATERIALS

- LEGO BLOCKS - JOLLY BOX 20X20X40 CM = 6 PCS - CARTON BOX 8X8X16 CM = 40 PCS - STOPWATCH = 3 PCS - STEP COUNTER = 2 PCS 2x4 = 100 PCS (RED) 2X4 = 200 PCS (BLUE) 2x2 = 100 PCS (YELLOW) 2X2 = 200 PCS (BLUE) 2x6 = 100 PCS (GREEN)

(4)

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

(5)

- 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

(6)

- 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

(7)

(8)

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

(9)

LAYOUT

QC OPERATOR 1

SUB ASSY BOTTOM

OPERATOR 2

SUB ASSY TOP

OPERATOR 3 FULL ASSEMBLY KEYMAN INTERNAL TRANSPORTATION TRUCK SUPERVISOR CUSTOMER

(10)

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

TURN OVER : PEOPLE 312500 TRANSPORT STEP 4:18

(11)

- 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

STAGE 2

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

(12)

RESULT OF STAGE 2

- EVALUATION AFTER THE END OF STAGE TWO

BATCH SIZE 10 3 PEOPLE 8 8 AREA 20 m2 _{20 m}2 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

TURN OVER : PEOPLE 312500 375000

LEAD TIME 4:18 1:26

(13)

- 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

STAGE 3

AND THEN “START” STAGE 3

- CHANGE BATCH SIZE IN TO 5 PCS - LAYOUT DECIDE AFTER DISCUSSION - SAME PEOPLE IN SAME POSITIONS - DURATION 8 MINUTES

(14)

RESULT OF STAGE 3

- EVALUATION AFTER THE END OF STAGE THREE

BATCH SIZE 10 3 5 PEOPLE 8 8 8 AREA 20 m2 _{20 m}2 _{20 m}2 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

TURN OVER : PEOPLE 312500 375000 625000

LEAD TIME 4:18 1:26 0:53

(15)

- 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)

STAGE 4

OWNER IMPROVEMENT NOTES

- CHANGE BATCH SIZE IN TO 1 PC

(16)

ONE PIECE FLOW LAYOUT

QC

OPERATOR 1

PRODUCE SHORT PRODUCT WITH 8 SEC TAKT TIME

OPERATOR 2

PRODUCE LONG PRODUCT

WITH 8 SEC TAKT TIME

SUPERVISOR+ KEYMAN

ASSURE PRODUCTION SYSTEM FLOW PREPARE CARTON BOX TO QC

SHORT LONG

CARTON BOX

FINISH GOODS BATCH SIZE 3 SETS

1L 1S

KANBAN

BLUE 2X4 50PCS YELLOW 2X2 50PCS BLUE 2X2 50PCS RED 2X4 50PCS BLUE 2X4 50PCS YELLOW 2X2 50PCS BLUE 2X2 50PCS GREEN 2X6 50PCS

TRANSPORT TO CUSTOMER

USE OUTSOURCING TRUCK COST 50000 / DAY

DELIVERY : 1 BOX L & 1 BOX S (BALANCE)

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

(17)

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

(18)

RESULT OF STAGE 4

- EVALUATION AFTER THE END OF STAGE FOUR

BATCH SIZE 10 3 5 1 PEOPLE 8 8 8 4 AREA 20 m2 _{20 m}2 _{20 m}2 _{8 m}2 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

(after 6 min) (-50000 truck)4950000

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

TURN OVER : PEOPLE 312500 375000 625000 1237500

LEAD TIME 4:18 1:26 0:53 0:24

(19)

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