The Lego Lean Game
Danilo Sato, Francisco Trindade
XP 2009 – Sardinia - Italy
25th May 2009
© ThoughtWorks 2008
•! Quick introduction
•! Simulating a production line
•! How about software?
Agenda
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•! Lean concepts starting to be noticed in the software world
•! But not everyone has had contact with Lean principles and practices
We’re here to introduce you to Lean
Hands On!
Why are we here?
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•! Toyota Production System
–! Revolutionized manufacturing (Ford vs. Toyota)
–! Started to be applied to different areas
•! Google, Dell, Zara, …
•! Product Development
•! Supply Chain Management
•! Software
•! Healthcare
•! …
Lean?
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•! Push and Pull Systems
•! Kanban
•! Systems Thinking
•! Flow
•! Heijunka
•! Yatai (Work Cell)
•! And more…
What we want to show
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•! Let’s simulate a production line…
Hands On – 1st Step
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•! 4 Teams •! 4 rounds of 40 seconds
•! Follow the instructions •! Build houses •! 1 Piece = $ 1.00 •! 1 House = $ 25.00
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•! Overproduction
•! Waiting
•! Unnecessary Transportation
•! Overprocessing
•! Inventory
•! Motion
•! Defects
7 Wastes of Manufacturing
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Push and Pull Systems
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•! Push System – upstream information
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Push and Pull Systems
© ThoughtWorks 2008
•! Push System – upstream information
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Push and Pull Systems
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•! Push System – upstream information
•! Pull System – downstream information
•! Physical device
•! Signals demand to downstream processes
•! Regulates demand on a pull system
•! Limits Work in Process (WIP)
•! Aids visual control
•! Self-directing
Kanban
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•! Using Pull and Kanban
–! Setup minimum buffers at intermediate steps
–! Demand comes first
–! Items are produced to fill gaps in the buffers
•! 4 rounds of 40 seconds
Hands On – 2nd Step
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•! Another type of waste
•! Some people working more than others
•! Mura (Unevenness)
•! Heijunka
Unleveled Process
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•! Final goal is a leveled process
•! Production line must be a continuous flow
•! One piece is bought when one piece is delivered
•! Sustainable pace
Flow
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•! Why does it still feel wrong?
•! What are the other teams doing?
•! What’s the purpose of the system?
Systems Thinking
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•! Why does it still feel wrong?
•! What are the other teams doing?
•! What’s the purpose of the system?
Systems Thinking
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•! Do we need 4 teams to build a house?
•! Teams 1 and 2 have overlapping tasks
Let’s Experiment
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•! Using Work Cells
–! Each person builds a house
–! Round of 160 seconds
–! Signal (raise your hand) if you finish your house
Hands On – 3rd Step
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•! Continuous Improvement
•! Reflect and adapt
•! Learn by standardizing
•! Long term thinking
•! Respect People
Kaizen
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•! Continuous Improvement
•! Reflect and adapt
•! Learn by standardizing
•! Long term thinking
•! Respect People
Kaizen
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Hands On – 4th Step
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•! Discuss your own process
•! 1 round for each team
•! We saw some of the practices
•! Practices are contextual
•! Underlying principles must be understood
–! Like agile!
Is That All?
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What is Lean?
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•! Manufacturing is not the same as Software Development
•! Lean Product Development
–! Knowledge flow is not the same as material flow
Lean in Software Development
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•! Extra Features
•! Waiting
•! Unnecessary Transportation
•! Gold Plating
•! Partially Completed Work
•! Unnecessary Movement
•! Defects
•! Unused Employee Creativity
Lean in Software Development
© ThoughtWorks 2008
(Overproduction)
(Waiting)
(Unnecessary Transportation)
(Overprocessing)
(Inventory)
(Motion)
(Defects)
Kanban
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Kanban
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•! Much more:
–! Eliminate Waste
–! Create Knowledge
–! Build Quality In
–! Defer Commitment
–! Deliver Fast
–! Respect People
–! Improve System
Lean in Software Development
© ThoughtWorks 2008
•! Lean:
–! Genchi Gembutsu
–! A3
–! 5 Whys?
–! Stop the Line
–! Andon
–! Jidoka
–! Mistake Proofing
Thank you!
Questions?
© ThoughtWorks 2008
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