lego simulation instructions - hamacher and...

© Hamacher and Associates, LLC – All Rights Reserved © Hamacher and Associates, LLC – All Rights Reserved

Dune Patrol - 7042

Lego Simulation Instructions

Continuous Improvement Curriculum

© Hamacher and Associates, LLC – All Rights Reserved

Dune Patrol Simulation

2

This simulation will have multiple rounds throughout

the course to give different cycles of learning:

Round 1 - Batch

Round 2 - U-build it flow

Round 3 - Team Lean Design

The batch round will be used to obtain baseline data.

Dune Patrol 7042 is a product made by Lego®


Supply and Equipment List

• Flip Chart(s) for recording metrics and presentation of standard work graphs

• 50 - 4” x 6” aluminum bread loaf pans for batch moves

• 100 re-closable (zip) freezer bags (7 x 8)

• 1 Pack Multi-Colored Post-it Notes for kanban squares

• Lego Model 7042 Dune Patrol (or similar – try to target sets with 30 to 40

pieces)

• Classroom tables available to run simulations

• Tape for defining work zones

• Hours glasses (one minute) or timers for ovens

• Table tents for station names

• Station specific laminated instructions

• Stop Watches for time study analysis and line balancing for each team (1

per team and 1 per observer – typically 4-6 watches)

• Camera for recording or pictures - optional

3


Round #1: Batch Baseline • Separate Lego Parts into Plastic Bags

• Setup Tables in Room per drawing on next slide or distribute parts around room in similar fashion

• Distribute Legos per next slide

• Review Rules of the game:

– 1 hour = 2 minutes

– Run time (one shift) = 7 hours (14 minutes)

– Economic Order Quantity = 5 piece batches

– Customer Demand 4 dune buggies/hr

– Cannot ship incomplete orders

– Customer will accept orders that were late in the next hour

– $150 penalty for a late order

– Oven cure for frame after step 6 = 0.5 hours = 1 Min

– Steering wheel and air tank melt - they must go on after oven cure

4


Round #1: Batch Layout

5

Station

1

Station

5

Station

3

Station

2

Station

4

Station

6

Insp.

& Pkg

7

Oven

Cust.

8

Steps 1-4

Steps 5-7

Steps 8-9

Step 10

Step 11

Assemble Driver

Place in Dune Buggy

Material Handler


Round #1: Assigning Roles

• Fill in roles with volunteers (use slide 7 as an outline for flip chart).

• Have a copy of the build instructions at each station (picture w/parts

list)

• Walk through the process and show class what should occur at each

workstation and the responsibilities of each role.

• Train assemblers by building a few Dune Patrols with them. Make

sure each assembler is comfortable with the operation.

• Each assembler is to build five units and then call for the material

handler to move units to the next station.

• Instruct material handler to respond to assemblers’ calls.

• Only the material handler can move parts.

• Inspector is stationed at the last station (#7).

6


Round #1: Batch Factory Roles

7

Assembler #1_____________

Assembler #2_____________

Assembler #3_____________

Assembler #4_____________

Supervisor ____________

Time Keeper ____________

Accountant ____________

Assembler #5_____________

Assembler #6_____________

Material Handler____________

Inspector ____________

Customer ____________

All others must document observations


Building Instructions

8


All Rounds: Lego Factory Scorecard

9

Fill in white spaces after each round

Batch U-Build-It Lean

Hours of Game 7 7 7

Employees 0 0 0

Total Labor Time 0 0 0

Time to 1st Unit 0:00 0:00 0:00

Total Units Produced 0 0 0

Buggies Shipped 0 0 0

Cycle Time in minutes (Total time/Units Produced) #DIV/0! #DIV/0! #DIV/0!

Revenue (Buggies Shipped* $100) $0.00 $0.00 $0.00

Late shipments 0 0 0

Late shipment penalty (-$150/shipment) $0.00 $0.00 $0.00

Labor Cost ($15*Census*Hours) $0.00 $0.00 $0.00

WIP Inv Qty (include FG) 0 0 0

WIP Inv $$$ (Pcs*$10) $0.00 $0.00 $0.00

Rework 0 0 0

Scrap 0 0 0

Escapes 0 0 0

COPQ (RWK $5,Scrap $10, Escape $25) $0.00 $0.00 $0.00

Profit or Loss $0.00 $0.00 $0.00

Productivity (Total Labor Time/Units Produced) #DIV/0! #DIV/0! #DIV/0!

Team A


All Rounds: Lego Factory Scorecard

10

Fill in white spaces after each round

Batch U-Build-It Lean

Hours of Game 7 7 7

Employees 0 0 0

Total Labor Time 0 0 0

Time to 1st Unit 0:00 0:00 0:00

Total Units Produced 0 0 0

Buggies Shipped 0 0 0

Cycle Time in minutes (Total time/Units Produced) #DIV/0! #DIV/0! #DIV/0!

Revenue (Buggies Shipped* $100) $0.00 $0.00 $0.00

Late shipments 0 0 0

Late shipment penalty (-$150/shipment) $0.00 $0.00 $0.00

Labor Cost ($15*Census*Hours) $0.00 $0.00 $0.00

WIP Inv Qty (include FG) 0 0 0

WIP Inv $$$ (Pcs*$10) $0.00 $0.00 $0.00

Rework 0 0 0

Scrap 0 0 0

Escapes 0 0 0

COPQ (RWK $5,Scrap $10, Escape $25) $0.00 $0.00 $0.00

Profit or Loss $0.00 $0.00 $0.00

Productivity (Total Labor Time/Units Produced) #DIV/0! #DIV/0! #DIV/0!

Team B


Round #1: Batch Run (Instructions)

• All parts given to assemblers (in bags) to allow WIP to accumulate

• Line is to start dry - no WIP inventory (first unit will measure through-put time)

• Oven is a non-interruptible process (must run for 1 min.)

• Operators to act like they are in separate rooms (departments)

• Give customer a model unit to compare deliveries

• Accountant will stand by day by hour sheet. Accountant to log time for first buggy complete in bag (through inspection) and first shipment of 4 buggies.

• Supervisor told to keep people working

• Customer can only talk w/supervisor (may complain a lot)

• Stop once in the middle of simulation to count WIP and finished goods. (Stop at the same time for all teams)

• Run game for 14min. Calling out each hour (two minutes)

• At the end of 14 minutes, call end of day. Add a couple of minutes “overtime” if no product has shipped yet, would like some product to ship.

11


Round #1: Batch Run (Outbrief)

• Have the accountant take the last count on cars built

• Accountant to count WIP (ANY & ALL assembled pieces

- including finished goods)

• Fill in the scorecard by filling in the white spaces (see

scorecard) after each round.

• Ask players how the game went and felt. Notice

responses of people who had varied cycle times

– Assembler with all the WIP

– Assembler who run out of parts

– Ask Material handler

– Have the observers add remarks asking to skip repeats

– Have everyone look at the factory. What do they see?

12


Round #2: U-Build-It Factory (Instructions)

• Divide the class into equal teams

• Each group will design a flow line

• Each group will concentrate on the activity of the product.

– “What are the four things a product can do?”

• Each team will design and run a flow factory

• Each team must staff the line with assemblers and material handler

• Be sure to analyze standard work (activity of the operator). Don’t

over analyze to achieve line balance

• Line will start dry to measure throughput

• Same rules as batch apply except no EOQ exists (line does not

have to build in batches of five). Customer still wants sets of four

• Oven continues to be a non-interruptible process (1 min cycle)

13


Round #2: U-Build-It Factory (Outbrief)

• Accountant to capture all data as in Batch run

• Fill in the score card and compare the results with batch

• How did the class handle the order of operations with the steering

wheel, air tank and oven cure?

• How did they handle the batch process of the oven?

• Where did the WIP pile up?

• Using the cycle times that were observed, ask each operator how

they performed

• How did the operators feel about this cell in comparison to the first

(batch) round?

• Does the cell look like it should to start the next day of work? (The

prize in the real world goes to the team that can run this cell day in

and day out.)

• “ARE WE THERE YET?”

14


Round #3: Team Lean Design (Instructions)

• This is the big one. You will now display all that you have learned.

• The cells must now be set up to run in a lean configuration.

• No EOQ but demand remains four per hour.

• The setup and layout must be robust to real world occurrences of temporary loss of an operator, overtime or extra orders by the customer

• The team leader will present the set up and describe the flow and work of the cell. Evidence of tools used must be shown via visual aids such as flip charts, PowerPoint, etc. Expected tools to be used:

– Takt time

– Standard Work, Control plan

– Process map

– Visual controls

– Kanban

– Mistake proofing, C&E matrix, FMEA

• Prepare a team practical exercise report to be turned-in at the last session describing the tools you used and how they influenced your cell design.

• You will be using members from the other team for your final run, so be sure to have clearly defined job responsibilities.

15


Round #3: Team Lean Design (Instructions)

• Hand in team practical exercise report

• Both teams will have 30 minutes to set up their factories

• Choose which team will run first

• Run through team presentations describing the flow and

work of the cells prior to running the simulations. Provide

visual aids showing tools used

• Capture all data on the scorecard and compare to prior

rounds

16


Round #3: Lean Design (Outbrief)

• Talk about strengths and weaknesses of the cell

• How did the team handle the creation of the work

standards?

• How balanced was the work?

• How did they handle problems?

• Did they use the tools?

• What are the features of the cells that add to their

robustness and ability to sustain?

• How could they improve the cell?

• Announce the winning team

17


Appendix Forms

• Standard Work Sheet

• Time Observation Sheet

• Percent Load Chart (Bar Chart)

• For more extensive training (more time or

multiple sessions):

– Standard Work Combination Sheet

– Process Capacity Table

18

© Hamacher and Associates, LLC – All Rights Reserved 19

Process Name: Standard Work Sheet Date:

Model Number: Scope of From: Dept: Supervisor:

Model Name:Operation

To:

Quality Safety Standard Work # of pieces of Std. Takt Operator

Check Precaution in Process Work-in-Process Time Number


Process: Observer:

Area: Date:Step Study Number ( Hr:Min:Sec) Lowest

# Operation 1 2 3 4 5 Repeatable Special Observation

1

2

3

4

5

6

7

8

9

17

18

19

Time For 1 Cycle

Time Observation Sheet


Process Name: Percent Load Chart (Bar Chart)

Model Number:

Model Name:

Date:

From: DepartmentSupr.Scope of

OperationsTo:


Product I.D.

Process Name

Standard Work

Combination Sheet

Date

Prepared Manual Automatic Walking Wait

Work Description Step

No. Operation Time (In seconds)

Totals

Dept

Volume

Takt Time

Piece

min sec

Operator Number __________

Time

Manual Auto Walk

Total Operating Time

Waiting


Net Operating Time (I) = Daily Requirement =

Date: Process: Part #: Page ________

Supervisor: Machine: Part Name:Max Output per

day: ________

Step #

Process

Description Mach #

Walk

Time

Manual

Time

A

Auto

Time

B

Mach.

C/T

C=A+B

# Pcs

D

Time to

Change

E

Time/

Piece

F=E/D

Total

Time

G=C+F

Total

Capacity

H=I/G Comments

1

2

3

4

5

6

7

8

9

10

11

12

Process Capacity Table

Base Time Tool Change Time

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