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Fun with Lean
Games and activities designed to teach Lean concepts
October 28, 2016
Hilary Bauman
Continuous Improvement Specialist
Wisconsin Lean Government Program
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October 28, 2016
Course objectives
• Learn how interactive activities can be good teaching
tools
• Take part in various activities designed to teach Lean
concepts
• Be able to lead simple Lean activities with a group
• Understand the Lean concepts being taught by each
activity
• Leave with instructions and resources for group
activities that demonstrate Lean concepts
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October 28, 2016
Why use games and activities?
• Activities allow everyone to participate, while also
allowing you to identify potential leaders within your
team.
• Activities often simulate real processes and allow
people to “play” without consequence.
• People learn best by doing. Activities make those
involved active rather than passive participants.
• Simulations drive home key Lean concepts and get
people thinking about waste after they return to
their desks.
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The penny game
Concepts: teamwork, flow, batching, customer satisfaction
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What you will need
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4-8 people per team
20 pennies per team
A watch or clock with a second hand
Paper and pencil for recording times
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How it works
• Each team should designate a timer, a customer and
at least two processors.
• The first processor should be given 20 pennies, all
with heads up.
• The timer should be ready to start timing the process
from start to finish.
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Next
• In the first round, use batch sizes of 20.
• The first processor must turn each coin over before
moving it to the next processor. Processors must use
their left hand to do this. Coins may not be moved to
the next processor until all 20 are flipped over.
• Continue this process until all processors have
completed their task and the coins are finally given
to the customer at the end. Record the lead time.
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Next
• In the next round, reduce the batch size to five
pennies. This change alone should significantly
reduce the time it takes for the pennies to reach the
customer. Record the time.
• In subsequent rounds, make more improvements,
including a “kaizen” to use both hands in flipping,
and reducing batch sizes even further.
• Times should reflect the improvements.
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Variations
• Variations can be made to this simple game,
including using different value coins and having them
processed in a particular order.
• The customer can also tell the team in which order
they prefer to receive their coins, or whether they’d
like them heads up or down, for example.
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Key points made by activity
1. Reducing batch size should reduce lead time. Strive
for one-piece flow in a process.
2. Using both hands results in more efficient work,
demonstrating using staff skills to their full
potential.
3. Customers should ultimately dictate how the
process works.
Source: http://www.leansimulations.org/2010/11/penny-game.html
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Lean team fun tip #1
If you’re having a full day meeting:
• Have it off-site in a place that encourages creative
thinking. Get away from the office.
• Ask each team member to bring an ingredient or two
for a pot luck. Tacos, chili or sub sandwiches are
some candidates and make good lunches. And no
one needs to bring too much.
• Start with an ice breaker. It might sound cheesy, but
it helps team members to get to know one another.
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Tennis ball game
Concepts: waste, process improvement techniques and
creative thinking
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What you will need
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5-8 people per team
3 tennis balls per team
A watch or clock with a second hand
Paper and pencil for recording times
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How it works
1. The team should first form a circle facing each
other.
2. The team should start with one tennis ball.
3. The ball must be tossed from one player to
another, but only to a player who has not yet
touched it.
4. Continue until the last team member has the ball.
5. This is your established process.
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Next
1. Use three tennis balls and send them through the
process in the exact order established in the first
round.
2. Time the process from start to finish and record
the time.
3. A dropped ball is a defect. The
process must start over from the
beginning if a ball is dropped.
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Next
1. Tell each team to significantly reduce the time it
takes for three balls to go through the process.
2. Allow a minute or two for the teams to discuss and
make changes to their process. Do not offer
suggestions.
3. Send three balls through again, timing the process.
4. See if there are further changes that can be made
to improve the time even further in another round
if there is time.
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October 28, 2016
Key points made by activity
1. The teams will likely come up with ways to
significantly improve the process without being
told specifically how to improve it.
2. The process will likely be improved by reducing
waste.
3. It’s vitally important for those who work with a
process to be directly involved in making
improvements to it.
Source: http://leaninsider.productivitypress.com/2008/12/tennis-ball-exercise.html
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October 28, 2016
Domestic Lean Goddess video
Concept: Lean wastes
Other videos address 5S and PDSA
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October 28, 2016
Peanut butter and jelly game
Concepts: error-proofing, clearly documenting processes
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What you need
• Teams of 4-5 people, with one acting as the
facilitator
• Loaf of bread
• Plate
• Knife
• Jar of peanut butter
• Jar of jelly
• Paper and pencils for notes
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October 28, 2016
How it works
• Set up the supplies in the front of the room.
• Divide participants into groups of 4-5. The facilitator
for each group should leave the room.
• Have each group prepare, write down and submit
the process for making a peanut butter and jelly
sandwich.
• The facilitator will follow the instructions strictly as
written. For example, if the instructions say to put
the peanut butter onto the bread, the jar should just
be laid on the bread.
• Debrief.
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October 28, 2016
Variations
• Instead of using a peanut butter and jelly sandwich as
the process, use another simple process like making a
paper airplane or a snowflake.
• Send the facilitator out of the room
and instruct each team to make a
snowflake or airplane, creating written
directions. When the facilitator
returns, he or she must follow the
directions exactly, with no clarification
allowed. The variation in end products
can be hilarious!
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October 28, 2016
Key points learned
• A process is only as good as its design.
• Result of a process can be dramatically altered by
just one or two steps.
• If we want to change the results of a process, we
need to change the process itself.
• Clear documentation of processes is important.
Source: National Quality Center Game Guide, 2006
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October 28, 2016
Lean team fun tip #2
• Take photos of your team at work and a group
picture that includes all of you.
• Use the photos in your communications and reportout.
• Keep the photos as a remembrance of the
experience of working together on your project.
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October 28, 2016
My Lean team
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October 28, 2016
5S Numbers Game
Concepts: 5S (sort, set in order, shine, standardize, sustain)
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What you need
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Numbers sheets for each person
Pen or pencil for each person
Clock or watch with second hand for timing
Flip chart for recording
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How it works
The current state of our workplace
• Use a pen or pencil to strike out the numbers 1 to 49
in the correct sequence.
• You will have 30 seconds to complete this task.
• When time has been called, each person will call out
the highest number crossed out. Those numbers will
be recorded on a flip chart.
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Discuss
• How do you feel about your score?
• What appeared to get in the way of achieving a
higher score?
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5S Step 1
• Our initial analysis indicated that numbers 50
through 90 are not essential to our daily tasks. They
have been removed from the work area.
• Repeat the strike out task again on the following
page.
• The same rules apply: strike out the numbers in the
correct sequence. You will have 30 seconds to
complete this task.
• Record highest number reached.
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Discuss
• How do you feel about your score this time?
• What appeared to get in the way of achieving a
higher score?
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5S Step 2
Set in Order
• We have installed some racks on the job site using a
3 x 3 grid.
• We have organized the numbers so that they are in a
sequential order in the racks.
• Strike out numbers 1 to 49. You will have 30 seconds
to complete this task.
• Record highest numbers reached.
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Discuss
• How do you feel about your score this time?
• What appeared to get in the way of achieving a
higher score?
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5S Step 4
Standardize
• Our analysis indicated that we needed a more
organized racking system, so we have reorganized
the numbers in a more standardized way.
• Strike out the numbers from 1 to 49 in sequential
order. You will have 30 seconds to complete this task.
• Record the highest number reached.
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Discuss
• How do you feel about your score this time?
• What appeared to get in the way of achieving a
higher score?
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5S and identifying quality issues
• We have recently learned that two of our numbers
are missing!
• You have 30 seconds to identify the two missing
numbers.
• Record how long it took to find them.
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This time … with 5S implemented
• Find the two missing numbers.
• You will have 30 seconds to complete this task.
• Record the time it takes to find them.
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Key points learned
• Work is more efficient when tools are organized and
standardized.
• It is easier to work in an organized workspace.
• A disorganized space can be overwhelming.
• 5S techniques can apply to various real and virtual
spaces.
Source: www.superteams.com
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Who’s here?
Concepts: collecting and displaying data
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What you need
• Teams of 3-5
• Chart paper and markers
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How it works
• If your team is unfamiliar with graphs and charts, you
may want to start with an introduction.
• Teams should be chosen from people “most like
themselves” (do not define this for them).
• Within the team, develop a question that could
characterize the entire room and be displayed
graphically (see examples) or provide each group
with a random question.
• Do not use any questions that may be too personal.
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October 28, 2016
How it works
• Each team should graphically represent themselves,
and then the same information from other teams.
• Discuss. Were the teams truly “most like themselves”
or were they not? How were differences displayed?
• Which team did the best job of displaying data and
why?
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October 28, 2016
Key points learned
• The game is simple and straightforward but forces
teams to think of data that can be graphically
displayed.
• Participants must think of the best way to display
data so that it can be understood.
• Groups learn that they are not always as alike (or as
different) as they might think.
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October 28, 2016
TRIZ
Concepts: Creative thinking, 1-2-4-ALL
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What you need
• Groups of 2-4 people
• Paper and a pencil for recording
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How it works
• In groups of 2-4, identify a process that needs fixing
(fictional or real).
• Take 10 minutes to:
▫ Identify an unwanted result for the process
▫ Make a list of all you can do to make sure you achieve
this unwanted result
• Identify things on the list that are already being
done.
• Share with the larger group.
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Things to keep in mind
• TRIZ should be approached with a spirit of fun; don’t
be afraid to laugh or suggest ideas you think might
be outrageous.
• TRIZ should be about stopping existing behaviors,
not starting new ones.
• Ask: “What must we stop doing to make progress on
our goals?”
• TRIZ is about clearing space for innovation.
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October 28, 2016
Variations
• Start with individuals, then have them work in
groups of two, then four, then everyone together
(1-2-4-ALL). This will encourage the more hesitant
participants to engage (especially in the 1-2
portion).
• Create action steps from the behaviors identified
that will be stopped.
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October 28, 2016
Benefits of TRIZ
• Speak the unspeakable in a safe way
• Make space for innovation
• Lay groundwork for creativity by doing hard work in
a fun way
• Can be used before or in place of visioning sessions
• Build trust by acting together to remove barriers
liberatingstructures.com
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October 28, 2016
Activities summary
Activity
Concepts
Tennis ball game
Waste, creative improvements for
processes
Penny game
Batching, flow, teamwork, customer
satisfaction
Domestic Lean Goddess video
Identifying Lean wastes
Peanut butter and jelly game
Clearly documenting processes
5S numbers game
5S (sort, set in order, shine, standardize,
sustain)
(If time) Who’s here?
Collecting and displaying data
(If time) TRIZ
Creative thinking, 1-2-4-ALL
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Open discussion and questions
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Other resources
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Domestic Lean Goddess video series
National Quality Center Game Guide
Big Book of Six Sigma Training Games
Lean Simulations
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October 28, 2016
For more information:
Hilary Bauman
Continuous Improvement Specialist
Wisconsin Lean Government Program
101 East Wilson Street, 9th Floor
Madison, WI 53703
(608) 266-0195
[email protected]
https://Lean.wi.gov