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Michigan Lean Consortium Lean 101 Exercise Instructions. Standard Work: Pig Exercise (facilitator). Read the initial instruction slide from the training presentation
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Michigan Lean Consortium Lean 101 Exercise Instructions
Standard Work: Pig Exercise (facilitator) • Read the initial instruction slide from the training presentation • Some will want more instruction, tell them something like “you told me during your interview that you knew how to do this! Get it done!”. Have some fun with it • After some time, when most are done, have the group hold up their pigs so you can see them. Walk around and make some funny comments! • Make sure to note that they are nothing like what we expect to have • Ask them why there is such variation. They will answer with “no instructions” or “didn’t know what you wanted” • Say ok, ok, we developed some instructions, here they are. • Hand out the instructions and let them try again with a new grid • Chances are that some will still struggle, and some will be close • After some time, get the groups attention and show them what the pig should look like • Have a discussion about what could still be done better with standard work • Move on to the rest of the slides , .
Standard Work (participants) • Draw the letter M above the top line, near the left intersection. The left and right leg of the M should rest on the top line, and the middle point of the M should be directly on the intersection • Draw the letter W under the bottom line, near the right intersection. The top right leg of the W should end at the bottom right intersection • Draw the letter W under the bottom line, near the bottom left intersection. The center point in the middle of the W should be at the bottom left intersection • Draw an upward facing arc. Start the left side of the arc at the bottom right leg of the M, and end the arc at the top right intersection • Draw a rightward facing arc. Start at the top right intersection and end at the top right leg of the W near the bottom right intersection • About 2/3 up the arc you just drew, draw a cursive letter e. Start on the arc and end to the right of the arc • Draw a downward facing arc. Start at the top right leg of the W that is near the bottom left intersection. End at the left leg of the W that is drawn near the bottom right intersection • Draw a circle in the middle of the box which is in the first column, middle row. The circle should be about 1/3 the size of the box • Draw a line from the top of that circle to the bottom left leg of the M which is near the top left intersection • Draw a line from the bottom of that circle to the top left leg of the W which is near the bottom left intersection • About 1/3 up the line you drew for step 9, draw a circle ½ the size of the first circle. The left edge of the circle should touch the right side of the line. • Inside that circle, draw a circle about ½ the size of the circle you just drew. The left edge of the new circle should touch the left edge of the other circle • Half way down the line which you drew in step 10, draw a small downward facing arc. The left edge of the arc should start on the line, and the right edge should be to the right of the line • Finally, draw 2 small circles next to each other inside the large circle which is centered in the middle row, left column
Count The F’s Exercise • Read the “Sorting and Inspection Co” slide • Inform the group that although they are not timed, the last person will be heckled! • Make sure you walk through the class and try and interrupt as much as possible! If they tell you to buzz off, ask if they ever get through a workday without an interruption! • Once the group has finished, run through the next slide in the main presentation. There are 47 F’s • Most of the group cant focus until they find them all. Give them a minute to review their work. Point out that almost all the F’s that are missed are in the word “of” • Once the group has regained focus, ask them about the exercise • Focus on the visual inspection piece of our daily work. How many of us use our eyes to inspect our work daily? • Refer to Deming’s theories that human inspection is only 80% accurate. • If we cant INSPECT quality into a system, what do we do? • Begin the discussion about building quality into the process. Error proofing , .
Numbers game exercise • Read the first numbers game slide, run the first round. • Ask how high the group counted, find the high and low numbers • Ask the group what the first S is – SORT • Show them the slide with all the extra numbers sorted out • Review pertinent slides about Sort • Run another round • Ask how high the group counted, highs and lows • Ask about the second S – Store / Shine • Numbers all look the same in the groups now that they are cleaned up • Review pertinent slides about Sort • Run another round, ask for the high and low numbers • Ask what is next – standardize. (2 slides) • All numbers are right reading and in proper order • Review pertinent slides about Sort • Run another round • Now on to visual management to help sustain (2 slides • Know where everything should go, can find something missing • Original slide is shown. Now it looks like total chaos. • Ask the group what this can apply to right now, today, in their daily jobs! , .
Improving your process Exercise • Have volunteer write name on board 5 times. This is not timed. • Ask how that process felt to them (normal, natural, have done it a lot of times!) • Now instruct the volunteer that you are going to improve his process. • Ask them to please write their name again, 5 times, but this time ONLY EVERY OTHER LETTER • Have them get to it, don’t let them think about it – you want them to struggle a bit • Eventually they will get it done. Thank them and have them sit down. • Ask them how that one felt (new, odd, strange) • Ask the larger group what they observed about the second round (at first it was slow, then it was fast) , .
