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Lean Simulation

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This topic contains 56 replies, has 27 voices, and was last updated by  Joe Boyle 10 years ago.

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  • #39586

    MJ
    Participant

    I am looking for a low cost or free Lean simulation to be used to train individuals on Lean basics.  Key messages include a pull system and 1 piece flow, and the ability to complete the exercise in 1 hour.  Any recommendations?  Thanks.

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    #120712

    BTDT
    Participant

    MJ:The Northwest Lean Networks has a couple of simulations for showing Lean principles. The first is called “The Cup Game”, this game was originally developed by Mike Studley.The second simulation, from Tim Leach (at Grumman?) involves making paper airplanes. They will provide you with instructions and sample results. I could not download the files, but they say they will send them to you for a minimum charge on CDROM (shipping and handling only).http://www.nwlean.net/Rath and Strong use a courier simulation called “Move It”. You may find some references to it.http://www.rathstrong.com/rs/pbuild/linkbuilder.cfm?selection=dn9.9.31Hope this helps.
    Your friendly neigbourhood BTDT

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    #120713

    JO CEO
    Participant

    Try the beer game or the lego game.

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    #120714

    Dayton
    Member

    It depends on how inexpensive, quick and simplistic you have to be.   If you want a good learning experience, I took a Lean course through MIT’s Lean Enterprise Consortium that used a Lean Enterprise Value game.  
     
    We used it throughout two weeks and it has quite a few modules or different learning objectives and scenarios.   It was very interactive and one of those games that have no right answers only best answers for specific situations.  It was Monopoly for operations geeks.  I was told that they’d sold or licensed it for general use before but it was not really “off the shelf.”   You might want to look into it – it was worth doing anyway.
     Vinny  

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    #120718

    Raincrow
    Participant

    I had the same question a few weeks ago.  After much searching, I decided to “do it myself”!  I developed a demo for a printing company using a series of rubber stamps and paper.
    It’s really not too difficult.  However, if you find something, please let us know.  I found MANY people anxious to sell a product, but none wanting to give specific demo designs/instructions for free.
    Good luck!!

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    #120724

    Tronan
    Member

    Use your production line.
    T.

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    #120775

    Mike Carnell
    Participant

    MJ,
    Check ou the dice game in Goldratt’s book. Get about 6 people in a line and we move lego’s based on the roll of a die. Then you truncate the distribution so a 1-3 is a 3 and 4-6 is a 4. You can get the message about throughput and variation reduction done in about and hour.
    Just my opinion.
    Good luck

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    #120805

    Tronan
    Member

    Goldratt’s book got bigger! He added stuff. Don’t you just hate it when you have to buy the same book twice due to pilfering students?
    Just wondering Mike, What differences have you found in the people you train when you do the classroom teaching against running simulations on the production line? Short term, and long term.
    T.

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    #121506

    Aussie
    Participant

    Thought I’d add my thoughts. I’ve run the “dice game” very successfully, but suggest a few additions to the original.
    First, run through the simulation with the full production line, each with a 1-7 die; it’s really important to keep a record of both total throughput and WIP (work-in-process), so that you can also estimate the total flow-time. Now, ask people how they might “improve” the process – you usually get a good range of ideas, that you can then work on.
    If anyone says to add more “units” at each point, that’s a capital solution; so give them another die each, so that each point can now run 2-12; of course, throughput might increase, but it doesn’t double (and you’d kind of like it to when you spend that sort of money), but the WIP increases a lot.
    If anyone says to “tweak” the process up, give them all prepared dice, each with the 1 converted to a 7; you’ll find minimal throughput increase, but again increased WIP.
    If someone actually hits on reducing variation (this is why I love this, because you can really get into Six Sigma messages as well as lean); then give them the 3-4 dice (I have some already made up with only 3s and 4s on them – buy blank dice and use a label-maker). Of course, the throughput certainly doesn’t decrease (it might even increase marginally), but the WIP goes down remarkably – in fact, it remains relatively stable, so imagine the savings in storage, WIP management (especially if you are FIFO) etc.
    Now, here’s the great thing. Try giving them some other dice to “play” the game with; I’ve got some that are 1-4 (they are actually pyramids – go to a gaming outlet). You’ll find that the throughput doesn’t decrease too much, but once again the WIP does.
    There are all sorts of dice that you can get to add an edge to the game.

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    #121513

    Mike Carnell
    Participant

    Tronan,
    I apologize for the late response. My schedule has definately affected my continuity on this trip.
    First – I don’t train very often. I am not a morning person and most people won’t hold class after lunch. (that is not a smart ass answer)
    We don’t do a lot of extra stuff other than catapults. We added the dice game recently and already the BB have gone to a random number generator instead of dice. We had a braai (barbeque) yesterday and had a couple of the Belts tell me they were at a point by Improve where they were saying “statapults again” so we will probably start looking for different ideas.
    Right now it is just statapults and projects.
    Regards

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    #121525

    Anonymous

    Mike,
    Have you heard of SAMES? You might want to check them out if you’re near Pretoria.
    Regards,
    Andy

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    #121526

    BBMole
    Participant

    Probably the easiest one I have seen is where you take several packs of cards and have each operator have to select various cards. You can easily make your own variations and it is cheap and easy to run. $2-$3 for each pack of cards (use a reasonable quality of card).
     

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    #121543

    Cook
    Participant

    We conducted Lean Office training and used a variation on an exercise that was provided to us by a consultant. The exercise (called DOTS) consisted of putting dots on a paper template (similar to the cups game). Our variation was to make it a new product introduction scenario where putting on the dots represented a step in the NPI process (VOC, design, pilot, financial analysis). Would be happy to send you the template and a few more details if you’re interested. UPDATED:DOTS_Unlimited.ppt [Power Point file]DOTS_Template.doc [Word file]

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    #121544

    Miles
    Participant

    Excuse my ignorance, but which Goldratt book is referred to here? I have only read The Goal.
    Thanks for your help. Miles

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    #121546

    Tronan
    Member

    Hi,
    Well you be needin to read it again.
    The dice game is from the Goal.
    T.

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    #121560

    Mike Carnell
    Participant

    Andy,
    I am about 60 km west of Pretoria so it is an easy stop. What is SAMES?
    Regards

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    #121561

    Mike Carnell
    Participant

    Dana,
    That has been around since the 80’s. Gary Flack used to do it.
    BTW Gary was a HP manufacturing guy. Guess Office Lean and Manufacturing Lean must be pretty close to the same thing?
    Just my opinion.
    Good luck

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    #121563

    Cook
    Participant

    “close to the same thing.”  Hmmmm.  Yes and no.  At a high level, the concepts are exactly the same.  But as you dig deeper, the types of issues you confront are often different and the tools most frequently used are different.  And certainly, the way you teach it has to be quite different because the audience is coming from a completely different frame of reference.  Would you agree?

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    #121566

    Mike Carnell
    Participant

    Dana,
    No.
    The only piece I might agree with is that the audience believes they are coming from a different place. If they spent less time justifyng that position they might find their company (and their customer) would be better off.
    Just my opinion.
    Good luck

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    #121569

    Cook
    Participant

    Mike,
    I need to understand your postition better.  Have you implemented Lean Office?  If so, did you implement TPM?  Did you use Kanban much?  If so, I’d be interested in knowing how.  So far (and I’ll admit we’re early in the game) those things haven’t made a lot of sense in the office environment.  And there are other topics that we will probably get into as we get more sophisticated (uch as takt time, pull, and OEE)but for now, they just confuse the real issue which is eliminating waste and improving flow.
    Regards,
    Dana
     
     

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    #121572

    Mike Carnell
    Participant

    Dana,
    Did I implement Lean Office? No. Have we done Lean in Office enviroments? Yes. Not only have I not implemented Lean Office I would fire anyone of our people who sold something called Lean Office because a Lean office isn’t any different than any other lean process. My co-author Barbara Wheat used to test her office for an acceptable level of organization/Lean by finding anything you asked for in 30 seconds. She leaned out her office just as she did any other facility. We have done in the last 8 months a hospital, a locomotive manufacturing facility, a hostile (place where people stay), IT help desk, setting explosive charges underground and plating out copper and the process doesn’t change.
    We don’t change the basics of what we do because someone works in and office or someone works in a factory. Maybe I don’t get it. How is a waste of Queueing different in an office than it is in a factory? How is a waste of motion different in a factory than it is in an office? There are at least 5 more where the answer is that they aren’t.
    Glad to see your eliminating waste and improving flow. Exactly how fast was it that you intended to make it flow? Any idea how to figure that out or do we just make it go as fast as we can. Even faster than the customer needs it so we can put it in a warehouse so it will always be there when they need it.
    Oops that isn’t Lean! So now we know it can go to fast and to slow and not be Lean so what is the right speed? Read about Takt time and pull before you do something stupid.
    Just my opinion.
    Good luck

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    #121574

    Cook
    Participant

    Nice.  I’m going to eliminate some waste – – communicating with you.

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    #121580

    JO Club CEO
    Participant

    Dana – forget Carnell and the rest of the “I know it all” gang….they don’t understand lean office which is why the mock you.Check out what GE Capital has done in Europe if you want to learn.

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    #121582

    Anonymous

    Mike,
    Its at a place called Koedespoort, East Pretoria.
    South African Micro-Electronic SystemsPO Box 15888Lynn EastPretoria 0039South Africa
    Tel: +27 12 333 6021Fax: +27 12 333 8071e-mail: support@sames.co.zaweb: http://www.sames.co.za
    http://www.sames.co.za/
    Regards,
    Andy

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    #121585

    Mike Carnell
    Participant

    Andy,
    Thank you. I will check it out.
    Regards

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    #121610

    Adam Bowden
    Participant

    JO club CEO – As usual you’re talking Boll**ks. I started implementing Lean about 20 yrs ago and can advise that Carnell and others have a credible level of experience.  I’m sure you’re a “Lean Master” – who certified you ?
    Adam
     

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    #121612

    Adam Bowden
    Participant

    MJ,
    The “card drop game” is a great way to simulate a business and is an effective way to teach most of the lean skills.  Cost – one pack of cards, a stopwatch, pens/paper and alot of fun !!!
    It should be “on-line” – if not e-mail me and I’ll send you a copy.
    Regards,
    Adam  Adam.Bowden@FirstDataCorp.com

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    #121629

    Anonymous

    Mike,
    While you’re there you should try some millie paap – it’s just grits without the grit.
    By the way, the research centre in Pretoria, the CSIR, used to be able to produce the largest single crystal diamond and CMT wafers in the world.
    Other companies to look out for are Tedelex and Eloptro. Unfortunately, I no longer have any contacts over there.
    Regards,
    Andy

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    #121657

    Cook
    Participant

    Thank you for the tip.  I’ll check it out.

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    #121721

    JO CEO
    Participant

    Bank of america certified me

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    #121726

    indresh
    Participant

    dana,
    would be obliged if you can send across the template and details of the dot game
     
    rgds

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    #121729

    dogsxxt
    Participant

    Carnell got experience in lean implematation?? Bullsxxt…
    He claimed he led Motorola lean campaign in 80/90s which was a failure project. No one in Motorola really bother what is lean until recently. 
     

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    #121730

    dogsxxt
    Participant

    Carnell’s track record in lean at Motorola was a joke anyway. A 5-billion Europe company hired us to do lean offic for them instead of using those self-promoted consultants in these forum.

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    #121731

    dogsxxt
    Participant

    Want to cooperate with my company if you a freelance or consultant? I have inquiries from 4-5 banks in Asia Pacific region for lean six sigma training and consulting services.

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    #121732

    Anonymous

    Dogsxxt,
    That’s not quite correct …
    MOS 3 implemented a pull system in 1985. As you know, waferfabs commonly use process self-assurance (one-by-one confirmation of lots) as part of their process control.
    Several fabs also use value stream mapping to illustrate the value of silicon during process, because many considered some of the later process steps, such as passivation etch, as non critical. Of course, these later stages are where all the value has been accumulated – a point that some Lean practitioners should take note of ….!!!!
    Cheers,
    Andy

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    #121736

    Markert
    Participant

    dog,
    What is it that you are trying to tell us?Is little Timmy in trouble down by the barn on Mrs. Johnson’s property? Should I get Pa to round up a group of townspeople to rescue him? Come on boy, this is important…….There’s a biscuit and a new chew toy in this for you once we rescue him….Help me to understand…..Bark once for yes, twice for no…..
    I doubt anyone minds your presence here, dogssxt. I certainly don’t, and you have shown your own brand of “point of view” in the past. You have certain MC given rights in this global forum to your misguided “opinion”. But to show up every couple of weeks with dribble like your response to Adam, and the other direct attacks you post, come on……….

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    #121740

    Darth
    Participant

    HA!  What a joke and you know that I know what that certification is all about.  Were you “certified” by Mark or the woman who has no real lean experience outside the bank or the Canadian who has since left?  Maybe it was the other guy…at least he has some decent lean experience and I respect his knowledge.  Maybe I was even lucky enough to have GB trained you!!!  Don’t dare throw stones at some of the other posters if that is your claim to credibility.

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    #121741

    Darth
    Participant

    Phil, I spoke with Dog’s vet and he informs me that someone hasn’t been taking his meds on a regular basis…..if you know what I mean.  Between him the the J O…….  come on.

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    #121744

    Markert
    Participant

    Darth, I’m afraid I don’t understand. What medication? Is it fleas? Dis-temper? Rabies? Dog breath? Canis familiaris erectile disfunction? Doggie depression? Did he unearth a dead statistician from the backyard and bring back a strain of the black plague? What did the vet say?
     

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    #121746

    Darth
    Participant

    I believe he said something about making him take a nap or was it having him sleep or now I remember, it was putting him to sleep.  Dog is useful for some distraction and amusement.  Hard to take him too seriously given his attitude.  Stay awake Phil, I sense some upcoming jousting with the J O CEO regarding his Lean credentials.  I think he put his foot in it this time.  Claiming he is a lean master certified by BOA is amusing.  Have Bob order a few extra cases of spray paint.

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    #121749

    Adam Bowden
    Participant

    Jo CEO,
    Glad to see you replied – You’ve got attitude which is a good thing – you’ll get on well on this forum.
    Regards,
    Adam

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    #121752

    Dog Sxxt
    Participant

    Isixsigma forum is came to almost useless with people think they are big boss in this forum.  At end of the day only a few idiots left and they have talking to each others.

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    #121760

    JO Club CEO
    Participant

    Darth my good man – I would have expected more from you.  You know the BOA quip was sarcasm, but funny how you to continue to trash what you once defended to the hilt.  Look up Rubicon consulting in the UK sometime, check out some of their case studies – real lean, not the junk you pushed at the bank or over-priced US consultants peddle to whomever is dumb enough to pay them.

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    #121762

    Dan Urquhart
    Participant

    What is the card drop game?

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    #121763

    Darth
    Participant

    I do believe we are in concurrence on this one.  Sorry I missed the tongue in cheek on the BOA quip.  I guess I rose too rapidly to the bait…good one…you got me.  Mark did have some good lean knowledge culled from years at Allied Signal.  Tim also has some good knowledge.  The other two are light.  Unfortunately, like with most of the approaches including DFSS, senior leadership knew better and diluted much of what the original group of MBBs attempted to do.  Yes, I did defend at the outstart when leadership deferred to our knowledge and experience but once Milton took over and knew better than the collective hundreds of years of SS experience, things started to change.  Those same folks are now driving training to the Web as the recent thread with Bill from Moresteam seemed to indicate.  I will reiterate over and over that people whose entire 20+ year careers are within one company might not be the best change agents for a process requiring out of the box thinking.  And with the departure of many of the SS people brought in from the outside and their replacements being the internal people I can only forsee greater inbreeding.  But, the good news is that it is no longer my problem although I feel badly for those left behind who are experiencing frustration and anxiety after dedicating so much to the effort.  Regards to the rest of the Club.

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    #121765

    Mikel
    Member

    I know Rubicon – they are a joke.

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    #121835

    Shaw
    Participant

    You are a joke.  What do you know about them?  Go check out any of their case studies…Pilkington, Tesa, etc….
     
    What’s your lean story?  Did you buy your certification from BMG?

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    #121837

    Adam L Bowden
    Participant

    Hi Stan,
    Just checked out their site – WOW they really are experienced in Lean/SS ;-)
    I’m sure you know what the acronym WOW is also :-)
    Regards,
    Adam

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    #121841

    Mikel
    Member

    Never been to a BMG course, if anything they learn from me.
    Who are you to think you know anything?

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    #121849

    Adam Bowden
    Participant

    Hi Dan,
    It is a simple excercise that can be used to show RTY, normal distribution, waste, batching and a whole host of other lean/ss tools / methods. It is a simple excercise and is a lot of fun – it also is a great way to show resistance to change and push an accelerated and empowered workforce how to drive improvements.  I could not find it on the internet – if you e-mail me I’ll dig out a copy of mine and e-mail it back to you.
    Regards,
    Adam  Adam.Bowden@FirstDataCorp.com

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    #128282

    Krauspe
    Member

    The trick is getting a game that is consistant enough to perform real metrics.  Paper games and smiley faces we tried early on were random. The LeanMan Lean Principles Car Factory simulation kit is very low cost and you actually assemble toy cars using various flow scenarios.  Lots of fun and the VA touch labor remains consistant throughout. Compact and easy to take around if you travel.

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    #131783

    Toyota man
    Member

    Dana
    I posted a seperate message (Reply To Dana)
    T Man

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    #146161

    Aquinas
    Member

    Hi Dan,
    Pls send me the simulation if possible.
    Rgds,
    Thomas

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    #157700

    Nirlep
    Participant

    hi danna
    I am an Industrial Engineer, working in a life science industry. I am trying to address the issues we have currently with our NPI process and sounds like we are in a same boat.
    I did looked at your presentations and word file. My email I d is nirlep.sanghvi@gmail.com
    I will really appreciate if you can discuss your NPI process and we can mutually help each other
     
    thanx
    Nirlep Sanghvi

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    #157736

    Cook
    Participant

    Nirlep,
    I am very busy right now – – going on vacation on Friday for two weeks.  If you contact me again in mid-July, I might be able to help.
    Dana

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    #157767

    Nirlep
    Participant

    DANA
    How can I contact you again
    can I have your email I D Mine is nirlep.sanghvi@gmail.com

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    #184040

    Joe Boyle
    Participant

    http://video.yahoo.com/watch/3008461/8599958
    Let me know if this helps-
    Faciliator Guide, partcipant workbooks, and BOM available that go with this lean simulation.  You will need to supply your own plastic pipe from local hardware store. 
    Joe Boyle
    906 228 8085
     
     

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