Purpose: To help demonstrate the lean principles

Time: 1 hour

Airplane Exercise

Materials Needed

• 1 Ream of white paper

• 1 Ream of color paper

• 1 Box of manila folders

• 1 package of post-it-notes

• 2 Stopwatches

• 2 Boxes of small paper clips

Preparation

• Prepare metrics flipchart (see slide 5)• Identify the number of positions for

round 1 • Identify layout for round 1

• Note: It may be helpful to have examples for each position for round 1 to help explain the process.

Airplane Instructions – Round 1

• 7 minute Round• Layout should be scattered and NOT make sense. Ie - position #1 by #5 etc. • Assign positions and show participants folds• Batch Size = 3 pieces of paper in each folder• Everyone should work on the folder with the lowest number first• At 2 minutes communicate to the 1st operator to start using colored sheets of

paper to indicate defects. Only Operator 4 can “see” the colored paper to indicate to Operator #1 to “Stop making bad parts”. At that time Operator #1 returns to using white colored sheets.

• Key to the airplane exercise is to have 1 person that has more folds than others to create a bottleneck (ie position #3 or #4).

• Calculate Lead-time by timing the first folder from beginning (operation #1 to finished goods)

• Prevent operators from making any improvements to the process (ie. moving station)

• Remember this should be a fun exercise for the team.

Record the following metrics each round

Metrics Round 1 Round 2

Number of Airplanes Shipped

WIP(Work-in-Process)

Rework

Lead-time

Metrics

• Number of Airplanes Shipped– For Round #1 you can not count any airplanes shipped until work is

completed for the total batch (3 airplanes) at the last station.• Work –in – Process

– Work-in-Process are all the airplanes in process but not complete. You need to count the total number of folders (folders with rework are included) x 3 pieces = Total WIP

– This metric is pointing out all the inventory that is clogging the system. • Rework

– Number of folders with colored paper x 3 pieces = Rework• Lead-time

– The time it takes the first batch to be produced. The time for the first batch for round 1 and 1st airplane for round 2 to be shipped. (Start the stopwatch when position #1 starts and stop the stopwatch when the airplane is shipped).

Position #1 •Insert 3 Sheets of Paper in the Folder

•Label for Folder

•Everyone should be working on lowest numbered folder first (First in First Out)

•Alert the first operator to start making bad parts at 2 min into the round

Position #2

• Fold all sheets of paper in half (per example)

Round 1 - Positions

Position #3

•Fold one corner to the center to create a triangle. Fold other side to create triangle

Position #4

• Fold paper side to center of paper

Round 1 - Positions

Position #5

•Fold corner to center

Position #6

• Fold other corner to center

Round 1 - Positions

Position #7

•Make a “dog ear” fold

Position #8

• Fold airplane in half

Round 1 - Assignments

Position #9

•Fold wings (make tip of are plane side flush)

Position #10

• Fold other side of wing

Round 1 - Assignments

Additional Positions for Round 1

• Position #11 – Add paperclip and write logo

• Position #12– Flight Test person – fly airplanes and track number of

airplanes shipped

• Position #13– Material Handler

• Position #14– Time keeper - tracks lead-time of 1st batch

• Position #15– Material Handler #2

Questions to the team: Functional silos – impact on quality/quantity

•Anyone want to be held accountable for production of whole team? Process knowledge – anyone know what others are doing? Batching – necessary because all workers are in separate places Who’s bored? Who’s not? De-bunk perception that your hardest workers are your best workers

Where is the bottleneck? How can you tell where the bottleneck is? Why is it a bottleneck?

How does this round mimic your work area today? (silos, workers who do one job, etc.)

Characteristics of Round 1– Product moves only in batch sizes of 3– All stations produce independently and work at maximum speed

– No communication between stations

– Material is pushed to next operation immediately when completed

Operation1

Operation2

Operation3

Lot size = 3

1

2 3

Lot size = 3

1

2 3

ROUND 1 Debrief: Batching & No connection between processes

Airplane Instructions – Round 2

• 7 minute Round• Balance operations to eliminate bottlenecks and non-value added activities• Eliminate the use of folders and post-it-notes• Use operator #1 as a value added operator and if applicable use material

handlers / timekeepers as value added operators• Improve layout to have operators in sequential order• Have visual aids for participants to reference• Batch Size = 1 = One Piece Flow• Use post-it-notes for a kanban (signal) –pacing line to slowest operation• At 2 minutes communicate to the 1st operator to start using colored sheets of

paper to indicate defects. Only Operator 4 can “see” the colored paper to indicate to Operator #1 to “Stop making bad parts”. At that time Operator #1 returns to using white colored sheets.

• Calculate Lead-time by timing the first folder from beginning (operation #1 to airplane shipped)

• Calculate Round 2 metrics

Debrief Round 2

Questions to ask in the debrief• What changed?• Why is a one piece flow better?• Why is cross-training better?• Do you know where imbalances are? How to

correct them?• Did you work harder?• Where are the best ideas coming from?

IF YOUR PLANE DIVES:Bend the elevators up a little orthrow the plane a little faster.

IF YOUR PLANE CLIMBS, SLOWS DOWN, THEN DIVES:Bend the elevators down a little or throw the plane a little slower.

IF YOUR PLANE VEERS TO THE RIGHT:Bend the rudder a little to the left.

IF YOUR PLANE VEERS TO THE LEFT:Bend the rudder a little to the right.

elevators

rudder

Fun Facts