just-in-time enterprise institute (jei) training...

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Just-in-time

Enterprise

Institute

(JEI)

Training

Simulations

&

Practical Exercises

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Training Focused “Hands-on” Simulations & Practical Exercises The following copyrighted training focused “hands-on” practical exercises (P.E.) and training simulations are

available to support internal client taught Lean Manufacturing and Just-in-time Logistics related continuous

improvement projects and kaizens. Each PE and training simulation is organized into transportable, on-site

employable kits designed to educate ten to twelve (10-12) improvement activity participants with

simultaneous use of three (3) kits designed to train from thirty (30 to thirty-six (36)) improvement project

participants.

Each PE / training simulation is described in terms of their Objectives, their Value as a training tool, their

Concept of Operation / Employment, the exercise’s timing, the number of participants exercised, required

exercise coaches, and the simulation’s transportability. Also discussed are the key lean manufacturing and

Just-in-time logistics principles and practices demonstrated during the simulation’s execution, titles of each

role playing participant, photos of the simulation(s) in operation, and physical floor layouts reflecting space

and table requirements for their optimal employment.

The term “stages” reflects training program scenario phases or “shifts” of operation. Thus, a two (2) stage

simulation will demonstrate functioning of the manufacturing / logistics system before integration of lean

principles and practices and after they are integrated to demonstrate the significant value lean principles

add to the system’s efficiency.

Employment of these PEs and simulations must be facilitated by trained Just-in-time Enterprise Institute

(JEI) exercise coach(s). However, these PEs / simulations are specifically designed to support and

reinforce in-house client taught continuous improvement seminar / discussion / education activities focusing

on specific lean manufacturing and just-in-time logistics flow principles. If desired by the client, the teaching

seminars can also be accomplished by JEI lean education coaches.

“Hands-on” Training Simulation & Practical Exercise Titles

1. 2-Stage Complete Enterprise Value Stream Flow 11-36 Participants…………………………………………….. 2

File: 2-Stage Complete ENTERPRISE VS Flow 30s Bead Sim


2. 1-Stage Multi-Tier “High-Mix” FIFO Sequenced Supply Chain Flow 11-33 Participants………………….. 7

File: 1-Stage MULTI-TIER SEQ SC Flow Sim

3. 1-Stage Plan-For-Every-Part (PFEP) Lego Vehicle Production Value Stream Flow &

Seven Pull Systems 11-33 Participants ………………………………………………………………………….. 11

File: 1-Stage PFEP PULL 3-Lego VEH MFG Flow Sim

4. 4-Stage Multi-Variant Lego Vehicle Manufacturing Value Stream Flow 35 Participants…………………15

File: 4-Stage 3-Lego VEH MFG VS Flow Sim

5. 2-Stage High Volume Multi-Variant Lego Go Cart Production Value Stream Flow11-33 Participants .. 19

File: 2-Stage Lego Go Cart MFG WIP VS Flow Sim

6. 6-Stage Game Fan Card Fabrication Value Stream Flow 12-36 Participants……………………………………23

File: 6-Stage UK-UA FAN CARD MFG Sim

7. 2-Stage Army-Navy Game Ticket Publication Value Stream Flow 13-26 Participants…………..………… 25

File: 2-Stage ARMY-NAVY Game Ticket Publication Flow Sim

8. 1-Stage Overcoming Monuments & Line Balancing Value Stream Flow 11-36 Participants ……………28

File: 1-Stage MONUMENTS-BALANCE Flow PE

9. 1-Stage Visual Control Board Production Management Exercise Unlimited Participants……………… 32

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File: 1-Stage VISUAL PC & MILK RUN Routing PE

10. 1-Stage ”Milk Run” Pick-Up Route Planning Exercise Unlimited Participants…………………….……………33


1. 2-Stage Complete “Enterprise” Value Stream Flow 11-36 Participants



Simulation Objectives: Reinforce lessons discussing the value of applying lean manufacturing and Just-in-

time logistics principles to the complete enterprise

Practical Exercise’s Primary Value: Reflects operation of a “complete” enterprise system including 1st tier

suppliers, in-bound supply chain, internal materials management, manufacturing administrative activities,

financial management systems, product production, out-bound distribution, and customer product receipt

Simulation Operational Concept: Bead bracelet manufacturing is planned, then production; managed,

financially controlled, manufactured along a balanced FIFO production line, and distributed to three

customers via a milk run distribution system in cadence with the customer’s takt requirements. Raw

materials are pulled into the company via a milk run inbound supply chain system. A 60 minute traditional

manufacturing enterprise operation shift documents a dysfunctional benchmark. A 75 minute second lean

manufacturing & just-in-time logistics principled shift demonstrates the significant improvement achieved

through integration of lean and JIT principles.

Simulation Exercise Timing: Traditional Flow Operations Shift: 60 minutes

Just-in-time Flow Operations Shift: 75 minutes

Simulation Players: 10-34 (Variations of the simulation enable configuration for from 10-34 participants)

Coaching Crew: 1-2 (1 instructor + 1 simulation facilitator)

Simulation Kit Portability: Simulation is packed in a single large suitcase transportable by air baggage or

FedEx / UPS

Products:

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Demonstrates Value of:

• Achieving Complete Enterprise Scope (e.g., Order, Custom Engineering, Supply Chain, Internal

Materials Management, Production, and Distribution Flow) Customer Support System Optimization

• Focusing “Holistically” on Designing the Entire Manufacturing Enterprise System to Balance Work

and Flow Products from 1st tier Suppliers through Manufacturing to the End Customers, “Make-to-

order”

• Integrating “Visual” Operations Planning & Management Devices to Enable “Orchestration” of

Product Flow

• Achieving First-in, First-out (FIFO) Sequential Flow & Timing through Progressive Enterprise System

Stages

• Installation of “right-sized” Time Buffers only where Variation Causes “Time” Delays to be

Unavoidable (e.g., shipping/transport, batch processing, etc.)

• Open Vertical and Horizontal Communication of Customer’s Needs and Problems and their

Resolutions at all Stages (i.e., Andon Problem ID & Correction Protocols)

• Connecting Continuous Flow Segments with Internal and Supply Channel Coupling and Smoothing

Pull Systems

• “Streamlining” and “Systematizing” all Components of Manufacturing Flow Tempo to Enable Launch

and FIFO Flow from Customer Order Launch through Delivery to Customers (i.e., pacemaker)

Progressive Simulation Beginning or Current State Map

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Progressive Simulation Ending or Future State Map

Simulation “Visual” Management Board Systems

Simulation Exercise in Operations

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Exercise Key Stakeholders: • General Manager • Director, Finance & Accounting • Customer Service Manager • Engineering Manager • Production Control Manager • Materials Manager • Material Handler • Supplier(s) • Customer(s) • Manufacturing Team Members (10) • 3rd Party Truckers (2) • Auditor (Optional) • Kaizen Facilitator (Optional) • Failure Analyst (Optional)

3 Simulation Kits = 3 X 11 Participants / Kit = 34 total Participant

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2. 1-Stage Multi-Tier “High-Mix” FIFO Sequenced Supply Chain Flow 11-33

Participants

File: 1-Stage MULTI-TIER SEQ SC Flow Sim

Simulation Objectives: Reinforce lessons discussing the value of applying lean manufacturing and just-in-

time logistics principles to enable sequenced First-in, First-out (FIFO) “High-Mix” materials flow from multi-

tier upstream suppliers directly to their final Customer end user points-of-use (POU)

Practical Exercise’s Primary Value: Demonstrates successful operation of a just-in-time (JIT) FIFO

sequenced high-mix materials flow from four 2nd tier suppliers through two 1st tier suppliers directly to the

customer’s POUs with no intervening delays. Three supply chain tiers are actively played as well as both

the truck and ship transport systems between them.

Simulation Operational Concept: High-Mix Bead bracelet manufacturing is planned then broadcasted to

four 2nd tier suppliers, operating at the customer takt tempo, launch orders (i.e., Pacemaker) for the

component parts of the bracelets. These component parts / subassemblies / components are transported

FIFO by truck to one of two 1st tier suppliers for added value. Each appropriate 1st tier suppliers adds value

to their sequenced FIFO subassemblies and ships them by ocean ship to the customer manufacturer for

assembly into a finished product. Needed basic raw materials are pulled from two 3rd tier suppliers to the

four 2nd tier suppliers through a two-bin kanban system. All transport links operate as “Milk Run” pick-up

and delivery systems.

Simulation Exercise Timing: Scalable sequenced high-mix multi-tier supply channel flow Demo: 120

minutes

Simulation Players: 11-33 (Each simulation set employs 10-11 players X 3 identical sets = 11-33

participants)

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Simulation Kit Portability: Two simulation kits are packed in a single large suitcase with the third in a

smaller suitcase. Both are transportable by air baggage or FedEx / UPS

Products:


• Achieving High-Mix Complete Enterprise Scope (e.g., Order, Supply Chain, Internal Materials

Management, Production, and Distribution Flow) Customer Support System Optimization

• Focusing “Holistically” on Designing the Entire Manufacturing Supply Channel System Flowing from

Upper Tiers of the Supply Chain all the way to the End User Customer’s POU

• “Right-sizing” and “Dedicating” all Sequential High-mix Components from Upper Tier Suppliers to the

End Customer

• Achieving Flow of Customer Required, “Time Based”, “Need Sized” “Work Units” (e.g., Product

Sets/Kits) from Upper Tier Suppliers through to End User Customers

• Achieving First-in, First-out (FIFO) High-mix Flow & Timing through Progressive System Stages

• Installation of “Right-Sized” Time Buffers only where Variation Causes “Time” Delays to be

Unavoidable (e.g., shipping / transport, batch processing, etc.)

• Open Vertical and Horizontal Communication of Customer’s Needs and Problems and their

Resolutions at all Flow Stages (i.e., Andon Problem ID & Correction Protocols)

• Connecting High-mix Continuous Flow Segments with Internal and Supply Channel Coupling and

Smoothing Pull Systems

• “Streamlining” and “Systematizing” all Components of Flow Sequencing and Tempo to Enable

Launch and Sustained FIFO Flow from Upper Tier Suppliers Directly to Points-of-use (POU) (i.e.,

pacemaker)

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Simulation Future State Flow Map (single Simulation Kit)

Simulation Physical Layout (single Simulation Kit)

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Exercise Key Stakeholders:

• Supply Channel Manager • 3rd Tier Supplier Operator(s) (1-2) • 2nd Tier Supplier Work Station Operators (4) • 1st Tier Supplier Sub-assembly Operators (2) • Transportation System Manager • 2nd & 3rd Tier “Milk Run” Driver • Auditor • Kaizen Facilitator (Optional) • Failure Analyst (Optional)

3 Simulation Kits = 3 X 11 Participants / Kit = 33 total Participants

3. 1-Stage Plan-For-Every-Part (PFEP) Lego Vehicle Production Value Stream

Flow & Seven Pull Systems 11-33 Participants

File: 1-Stage PFEP PULL 3-Lego VEH MFG Flow Sim

Simulation Objectives: Reinforce lessons discussing the value achieved by integrating differing pull

systems to connect continuous flow segments of a manufacturing enterprise system

Practical Exercise’s Primary Value: Reflects operation of a multi-variant (i.e., High-Mix), progressive

stage manufacturing system employing multiple approaches to “pull” required assembly materials to these

stages based on the types and volumes of raw materials required at each stage. Thus, reinforcing the

necessity of creating a “Plan” for “Every” “Part” (PFEP).

Simulation Operational Concept: Orders in differing proportions, for three Lego vehicles are launched

along a FIFO flowing production system. At each stage, a different pull system is employed to pull assembly

parts and subassemblies to the main line production’s points-of-use (POU). Signal kanban, ConWIP

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kanban, “2-bin” kanban, recurring “kit” kanban, and “just-in-time” kanban are employed based on the

system’s PFEP. Additionally, two different approaches are employed to synchronize feeder processes

flowing to the main production flow. Two different approaches to internally delivering required materials to

support production are employed reinforcing the value of employing a “water spider” approach to materials

handling.

Simulation Exercise Timing: Plan-for-every-part (PFEP) simulation Exercise: 120 minutes



Simulation Kit Portability: Two of the simulation kits are packed in a single large suitcase with the third kit

packed in a smaller suitcase. All are transportable by air baggage or FedEx / UPS

Products:


• Shortening Lead Time through Achieving Flow • Operating at the Customer Takt Tempo • Importance of Balancing (Right-Sizing) each Stage of Flow • Buffering around Bottleneck Stages • Smoothing & Pacing Multi-Variant Product Flow • Achieving First-in, First-out (FIFO) Flow • Aggregating Stages into Cells • Eliminating changeover Time Penalties • Visual Production Management • Standardizing Activities • Achieving Quality at the Source • Constant Work-in-Process (ConWIP) Kanban Systems • Designing Flow Systems so they Run on Autopilot • Absorbing Minor Variations through Pull Systems • Synchronizing Materials Delivery Tours with Production Cycles • 2-Bin, 2-Bin “Kit”, 1-Bin JIT “Kit”, ConWIP, and Signal Kanban Systems • Managing via “Pull” versus Materials Requirements Planning (MRP)

Simulation Physical Layout (single Simulation Kit)

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Exercise Key Stakeholders: • Value Stream Manager • Work Station Operators (4) • Sub-assembly Operators (2) • Water Spider Materials Handlers (2) • Supermarket Picker(s) (1-2) • Auditor • Kaizen Facilitator (Optional) • Failure Analyst (Optional)


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4. 4-Stage Multi-Variant Lego Vehicle Manufacturing Value Stream Flow 35

Participants

File: 4-Stage 3-Lego VEH MFG VS Flow Sim

Simulation Objectives: Reinforce lessons discussing the value of applying lean manufacturing and Just-in-

time logistics principles to the manufacturing enterprise

Practical Exercise’s Primary Value: Reflects operation of a “Complete” enterprise system including

Production planning & control, internal materials management, and product production

Simulation Operational Concept: Three variants of Lego vehicles are manufactured, first, via a traditional

disconnected departmental method and benchmark performance metrics are captured. Then the same

vehicles are produced progressively operating under four incrementally improving lean transformation

stages. Each stage’s simulation production run is coupled to and supported by explanatory seminar

presentations and discussions of the lean principles and methodologies being integrated into the

manufacturing processes at that stage. During each progressive simulation run, improving performance

metrics are captured to demonstrate the value that the stage’s focus lean principle provides toward

increasing customer value. Each training seminar and progressive simulation cycle / run requires

approximately fifty minutes to complete. Thus, this simulation can be employed only within at least a two

day long training program.

Simulation Exercise Timing: All four of the progressive simulation segments require approximately sixty

minutes each to complete the training and simulation run components

Simulation Players: 20-35

Coaching Crew: 4 (1 instructor + 3 simulation facilitators)

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Simulation Kit Portability: Simulation is packed in two plastic transport chests, each transportable by air

baggage or FedEx / UPS


• Shortening Lead Time through Achieving Flow • Operating at the Customer Takt Tempo • Importance of Balancing (Right-Sizing) each Stage of Manufacturing Flow • Smoothing & Pacing Multi-Variant Product Flow • Achieving First-in, First-out (FIFO) Sequential Flow • Aggregating Production Stages into Cells • Eliminating or Reducing Changeover Time Penalties • Visual Production Planning & Management • Standardizing Activities • Achieving Quality at the Source • Integrating Constant WIP (ConWIP) Kanban Systems • Designing Flow Systems so they Operate Autonomously • Absorbing Minor Variations through Pull Systems • 2-Bin and Signal Kanban Systems • Managing via “Pull” versus Materials Requirements Planning (MRP)

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Simulation Exercise Beginning Current State Map

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Simulation Exercise Final Future State Map

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Exercise Key Stakeholders: • Plant Manager • Water Spider Materials Handlers (3) • Tool Crib Operator • Work Station Operators (17) • Supplier Operators (2) • Shipping Operators (2) • Customer (2) • Auditor (3) • Kaizen Facilitator (Optional) • Failure Analyst (Optional)

1 Simulation Kit = 35 total Participants

5. 2-Stage High Volume Multi-Variant Lego Go Cart Production Value Stream

Flow

11-33 Participants

File: 2-Stage Lego Go Cart MFG WIP VS Flow Sim

Simulation Objectives: Reinforce lessons discussing the value achieved by employing product focused

manufacturing cells and making products to specific customer orders

Practical Exercise’s Primary Value: Reflects operation of a multi-variant, progressive stage manufacturing

system employing multiple approaches to smoothly pulling work-in-process (WIP) through progressive

standardized and balanced work stations / centers, in a first-in, first-out (FIFO) “Make-to-Order” sequence,

at the customer’s order tempo without the need for inventory at any stage.

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Simulation Operational Concept: Two variants of Lego Go Carts are manufactured, first, via a traditional

disconnected departmental method and benchmark performance metrics are captured. Then the same Go

Carts are produced in a lean principled, continuous flow focused cellular work center approach. During both

progressive simulation cycles / runs, improving performance metrics are captured to demonstrate the value

that the application of lean principles provides toward increasing customer value. Each training seminar and

progressive simulation run requires approximately seventy minutes to complete. Thus, this simulation can

be employed only within at least a one (1) day long training activity

Simulation Exercise Timing: Make-to-Order Cellular Manufacturing Simulation Exercise:

Traditional Manufacturing Shift: 90 minutes

Lean Manufacturing Shift: 70 minutes



Simulation Kit Portability: All three of the simulation kits are packed in plastic tubs and can all be packed

in a single large suitcase and transported by air baggage or FedEx / UPS

Product:


• Achieving Flow Sequentially through Multiple Progressive Work Stations • Shortening Lead Time through Sequential Flow • Smoothing & Pacing FIFO Multi-Variant “Make-to-order” Product Flow • Operating the Entire System at the Customer’s Takt Tempo • Importance of Balancing (Right-Sizing) each stage of Progressive Flow • Achieving First-in, First-out (FIFO) Sequential Flow • Elimination of Inventory Requirements • Visual Planning & Production Management • Standardizing Sequential Flow Activities • Achieving an Effective Problem Recognition and Solution Andon System • Achieving Quality at the Source • Managing via “Pull” versus Materials Requirements Planning (MRP) Routings

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Simulation Exercise Beginning Current State Map

Simulation Exercise Beginning Current State Operational Layout

Simulation Exercise Final Future State Map

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Simulation Exercise Final Future State Operational Layout

Exercise Key Stakeholders: • Value Stream Group Leader • Customer • Production Operators (6) • Stockroom Operator • Shipper • Auditor • Kaizen Facilitator (Optional) • Failure Analyst (Optional)


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6. 6-Stage Game Fan Card Fabrication Value Stream Flow 12-36 Participants

File: 6-Stage UK-UA FAN CARD MFG Sim

Simulation Objectives: Reinforce lessons discussing the value of applying cellular lean manufacturing and

pull systems principles within a “Make-to-Order” publishing or manufacturing system

Practical Exercise’s Primary Value: Reflects integration of lean principles and techniques during

operation of a “plant wide” manufacturing system including production planning & control, internal materials

management, and multi-value stream product manufacture

Simulation Operational Concept: Two variants of Fan Card products are manufactured, first, via a

traditional disconnected departmental method and benchmark performance metrics are captured. Then the

same Fan Cards are produced progressively operating under five incrementally improving lean

transformation stages. Each stage’s simulation production run is coupled to and supported by explanatory

seminar presentations and discussions of the lean principles and methodologies being integrated into the

manufacturing processes at that stage. During each progressive simulation cycle / run, improving

performance metrics are captured to demonstrate the value that the stage’s focus lean principles provides

toward increasing customer value. Each progressive simulation cycle / run requires approximately sixty

minutes each to complete. Thus, this simulation can be employed only within at least a day long training

program.

Simulation Exercise Timing: All six of the progressive simulation segments require approximately sixty

minutes each to complete the training and simulation run components

Simulation Players: 12-36


Simulation Kit Portability: The three simulation kits are contained in three plastic boxes. All three

simulation kits are packed into a medium size suitcase for transport by air baggage or FedEx / UPS

Products:


• Smoothing Demands Placed on the Sequential Flow System • Leveling and Regulating Customer Demands • Pacing Production Activities to Exactly Match the Customer’s Requirements • Achieving First-in, First-out (FIFO) Sequential Single-piece-flow Manufacturing Systems • Advantages of Shortening Flow Lead Time • Advantages of “Pull” Manufacturing Systems • Aggregating Work Tasks into Cells (Cellular manufacturing) • Standardizing all Value Stream Activities • Eliminating or Reducing Changeover Time Penalties

Closed End

Staple

Open End

Staple

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• Value of “Right-sizing” Sequential Stages Throughout the Flow • Balancing Work Throughout the Flow • Eliminating Internal Flow Inventory • Dedicating Shared Resources to Each Value Stream • Continuously Improving Activities Through Lean Transformation

Progressive Simulation Exercise Beginning Current State Operational Layout

Progressive Simulation Exercise Final Future State Operational Layout

Exercise Key Stakeholders: • Water Spider Materials Handler • Work Station Operators (7) • Warehouse Operator • Auditor • Kaizen Facilitator (Optional) • Failure Analyst (Optional)

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7. 2-Stage Army-Navy Game Ticket Publication Value Stream Flow 13-26 Participants

File: 2-Stage ARMY-NAVY Game Ticket Publication Flow Sim

Simulation Objectives: Reinforce lessons discussing how to apply value stream mapping to assist in improving a “Make-to-Order” publishing or manufacturing system by applying lean manufacturing and pull systems principles Practical Exercise’s Primary Value: Guide participant teams through the process of assessing current state manufacturing operations, then designing a significantly improved future state vision through application of lean manufacturing and just-in-time logistics principles and techniques. Simulation Operational Concept: Four unequal work content variants of game tickets are fabricated at differing rates through a traditional disconnected functional departmental based process and benchmark performance metrics are captured. Participant kaizen team(s) document the current state and, after learning and discussing lean improvements, design an aggressive, yet feasible, future state vision and reengineer the fabrication process to reflect these improvements. This improved future state is documented, the lean game ticket fabrication system is exercised and its performance captured, then, a learning review is accomplished. Training, discussions, map construction, and exercise of the simulation for both current and future states requires approximately six hours. Thus, this practical exercise and simulation can be employed only within at least a day long training activity. Simulation Exercise Timing: Both of the progressive training, discussions, mapping, and simulation segments require approximately three hours each.

Training & Simulation Players: 12-26 Coaching Crew: 1-2 (1 instructor + 1 simulation facilitator)

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Simulation Kit Portability: The two simulation kits are contained in a single medium size suitcase for transport by air baggage or FedEx / UPS

Products:


• Achieving Flow through Multiple Sequential Work Stations • Shortening Lead Time through Achieving Flow Through Production Steps • Achieving FIFO Single-Piece-Flow versus Batch Processing • Operating at the Customer Takt Tempo • Balancing (Right-Sizing) each Stage of Progressive Flow • Smoothing & Pacing Multi-Variant Product Manufacturing • Achieving “Pull” between Flow Segments

• Aggregating Separate Manufacturing Stages into Cells • Eliminating or Reducing Changeover Time Penalties • Eliminating Requirement for Internal WIP Inventory • Visually Planning & Managing Production • Standardizing Value Stream Activities • Achieving Quality at the Source • Designing Flow Systems so they Operate Autonomously • Absorbing minor Variations through Pull Systems • Managing via “Pull” versus Materials Requirements Planning (MRP) Routings

Progressive Simulation Exercise Beginning Current State Operational Layout

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Simulation Exercise Beginning Operational Layout

Exercise Key Stakeholders:

• Value Stream / Group Manager • Water Spider Materials Handler • Work Station Operators (8) • Supermarket Operator • Customer • Auditor • Kaizen Facilitator (Optional) • Failure Analyst (Optional)


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8. 1-Stage Overcoming Monuments & Line Balancing Value Stream Flow

11-36 Participants

File: 1-Stage MONUMENTS-BALANCE Flow PE

Simulation Objectives: Reinforce lessons discussing the value of balancing work content and time

requirements over each progressive stage and installing “leveling” buffers before and after monument (e.g.,

bottleneck) stages along a manufacturing flow.

Practical Exercise’s Primary Value: Demonstrates successful operation of a “leveled” and “balanced” just-

in-time (JIT) FIFO sequenced work-in-process (WIP) flow along a dedicated production value stream.

Simulation demonstrates the value of installing correct size WIP buffers before and after delaying monument

processes to enable customer takt tempo flow through the monument’s stage of the operations..

Simulation Operational Concept: leveled demands for three variant bead bracelet products are launched

at the beginning of the manufacturing value stream and flow FIFO through progressive value adding stages.

Each of the progressive stages require equal work (i.e., work is balanced), thus, WIP is indexed every 90

seconds through successive manufacturing stages at the designed customer takt tempo of 90 seconds.

Each of two monument (i.e., bottleneck) drying ovens (each requiring 180 seconds with a capacity of two)

are buffered before and after with .WIP three staging spaces. Simulation demonstrates how this designed

buffering enables WIP to flow through the monument at the customer defined takt tempo, or through-put rate

(TPR), with a product exiting every 60 seconds.

Simulation Exercise Timing: Scalable monument buffered flow Demo: 75 minutes

Simulation Players: 10-36 (Each simulation set employs 10-12 players X 3 identical sets = 10-36

participants)

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Coaching Crew: 1 (instructor / simulation facilitator)

Simulation Kit Portability: Three simulation kits are packed in a single small suitcase which is

transportable by air baggage or FedEx / UPS

Products:


• Shortening Lead Time through Sequential Flow

• All Operations Functioning at the Customer Defined Takt Tempo

• Importance of Balancing (Right-Sizing) each Stage of Work-in-process (WIP) Flow

• Buffering around Monument (e.g., Bottleneck) Production Stages

• Smoothing & Pacing Multi-Variant Sequential Product Flow

• Achieving First-in, First-out (FIFO) Sequential Flow

• Aggregating Successive Stages into Cells

• Eliminating or Reducing Changeover Time Penalties

• Visual Planning & Production Management

• Standardizing Individual and Cell Team Activities

• Employment of Constant WIP (ConWIP) Kanban Systems

• Designing Flow Systems so they Run Autonomously

• Absorbing minor Variations through Pull Systems

• Managing via “Pull” versus MRP

Progressive Simulation Exercise Beginning Current State Map

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Progressive Simulation Exercise Beginning Value Stream Work Balance

Progressive Simulation Exercise Final Value Stream Work Balance

Simulation Exercise Beginning Current State Operational Layout

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Simulation Exercise Final Future State Operational Layout

Exercise Key Stakeholders: • Value Stream Manager • Work Station Operators (9) • Water Spider Materials Handler • Auditor (Optional) • Kaizen Facilitator (Optional) • Failure Analyst (Optional)


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9. 1-Stage Visual Control Board Production Management Exercise Unlimited

Participants


Simulation Objectives: Reinforce lessons discussing how to visually manage / orchestrate lean

manufacturing operations by visually planning four days manufacturing production

Practical Exercise’s Primary Value: Exercises thinking necessary to visually plan manufacturing

operations considering the lean principles of demand leveling, production regulation, work and time

balancing, and flexibly adjusting to changes in production capacity.

Simulation Operational Concept: Participants are exposed to an exercise scenario and asked to design a

production sequence which satisfies all of the required lean manufacturing principles and practices.

Simulation Exercise Timing: Participants are allowed approximately twenty minutes to complete the

practical exercise.

Training & Simulation Players: Individual or learning partner efforts

Coaching Crew: 1 instructor

Practical Exercise Kit Portability: Laminated exercise cards are transported in a plastic box


• Visually managing production to ensure “balanced” & “right-sized” work all along the production

value stream

• Shortening Lead Time through Sequential Flow

• Operating at the Customer Defined Takt Tempo

• Buffering around Monument (e.g., Bottleneck) Stages

• Smoothing & Pacing Multi-Variant Sequential Product Flow

• Achieving First-in, First-out (FIFO) Sequential Flow

• Integration of Pull (Kanban) Systems

• Absorbing minor Variations through Pull Systems

Practical Exercise Value Stream Flow Map

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Practical Exercise Visual Management Board Template

10. 1-Stage ”Milk Run” Pick-Up Route Planning Exercise Unlimited Participants


Simulation Objectives: Reinforce lessons discussing how to plan and manage a just-in-time inbound

transport “milk run” raw materials pick-up system for four day’s manufacturing production

Practical Exercise’s Primary Value: Exercises thinking necessary to plan a realistic “milk run” supplier

raw materials pick-up process. Completion of this practical exercise reinforces the value of “milk run” pick-

up route systems and teaches the participant how to accomplish the route planning segment

Simulation Operational Concept: Participants are exposed to an exercise production scenario and asked

to design, on a laminated pick-up route card, “milk run” raw materials pick-up routes which satisfy all of the

required just-in-time logistics principles and practices.

Simulation Exercise Timing: Participants are allowed approximately twenty minutes to complete the

practical exercise.

Training & Simulation Players: Individual or learning partner efforts

Coaching Crew: 1 instructor

Practical Exercise Kit Portability: Laminated exercise cards are transported in a plastic box


• “Milk Run” Inbound Raw Materials Supplier Pick-up Route Systems

• Shortening Supplier to Customer Points-of-Use (POU) Lead Time through Achievement of Flow

• Operating Supply Channels at the Customer Defined Takt Tempo

• Importance of Balancing (Right-Sizing) Each Stage (tier) of Supply Channel Flow

• Buffering around Supply Channel Monument (e.g., Bottleneck) Stages

• Smoothing & Pacing High-Mix, Multi-tier Supply Chain Flow

• Achieving First-in, First-out (FIFO) Sequential Supply Channel Flow

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• Visual Supply Channel Planning & Management

• Designing Supply Channel Flow Systems so they Run Autonomously

• Absorbing minor Supply Channel Variations through Pull Systems

Practical Exercise Supply Channel Value Stream Map

Practical Exercise Supply Channel Pick-up Route Planning Template

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