The Lean Experience Factory simulation - materials

1. The Lean ExperienceFactory simulation - materials

2. Checklist – Factory simulation materials • Templates folder • Circuit boards – 120 (3 rounds X 15 orders X 2 sheets/order + 30% buffer + 5 sheets for round 4) • 7 packets of dots – 2 Green, 2 Blue, 2 Red, 1 White – 1,000 each colour (3 rounds X 15 orders X 50 dots +30% buffer + 30 for round 4)/3 colours • Box – 4 scissors, 5 stopwatches, 1 caliper, discs • Dice – 2 customer, 20 standard dice • Changeover timers • Maintenance toolboxes (2) • Paper cutter • DVD’s – Creating a Lean Culture and What Lean Means

3. Checklist – round 1 Customer • Label • Work instruction • 2 dice • Stopwatch • Customer order log sheet Production Control • Label • Work instruction • Post-it notes • Prod Cont order log sheet Warehouse • Label • Work instruction • Circuit boards • Nano dots Fusing • Label • Work instruction • 2 dice • 2 orange changeover timers Laser Cutting • Label • Work instruction • 2 green scissors • 2 dice • 2 black changeover timers Sorting • Label • Work instruction Shipping • Label • Work instruction Maintenance • Label • Work instruction • Maintenance toolbox • 2 stopwatches • Maintenance log sheet Quality • Label • Work instruction • Quality log sheet Continuous Improvement • Label • Work instruction • 2 stopwatches • CI observation sheet Material handling • Label • Work instruction Plant manager • Label • Work instruction

4. Checklist – round 3 Customer • Work instruction • 2 dice • Stopwatch • Customer order log sheet Production Control • Work instruction • WIP storage labels (3) • FG storage labels (3) Warehouse • Work instruction • Circuit boards • Nano dots • POUS labels (4) Fusing • Work instruction Laser Cutting • Work instruction • 2 blue scissors Shipping • Work instruction Maintenance • Work instruction • Maintenance toolbox • 2 stopwatches • Maintenance log sheet Quality • Work instruction • Quality log sheet Continuous Improvement • Work instruction • 2 stopwatches • CI observation sheet Material handling • Work instruction Plant manager • Work instruction

5. Checklist – round 4 Customer • Work instruction • 2 dice • Stopwatch • Customer order log sheet Production Control • Work instruction • FG storage labels (1) Warehouse • Work instruction • Circuit boards • Nano dots • POUS labels (4) Fusing • Work instruction Laser Cutting • Work instruction • 2 blue scissors Shipping • Work instruction Maintenance • Work instruction • Maintenance toolbox • 2 stopwatches • Maintenance log sheet Quality • Work instruction • Quality log sheet Continuous Improvement • Work instruction • 2 stopwatches • CI observation sheet Material handling • Work instruction Plant manager • Work instruction

7. Template checklist – round 1

8. Template checklist – round 3

9. Template checklist – round 4

10. Data sheet checklist

11. Customer

12. Purpose As the customer, you will place an order every minute for 15 minutes. You expect “on time” delivery (note 1 below) and 100% quality (note 2). Materials A stopwatch to time the orders & delivery. 2 large dice to roll for orders + 6 coloured dots and 6 white dots (refer notes 4 & 5). Customer order log sheet to record the orders, delivery times and any quality issues. Procedures Orders Announce the start of the round. Roll the 2 dice to determine the order (note 3 & 4) Tell the Production Controller the order Record the time, type & quantity on the “Order log sheet” Repeat steps 2-4 exactly one minute apart until the round is complete one minute after the 15th order. Announce the end of the round. Deliveries When a delivery is received, check for the correct delivery (note 1) and quality (note 2). If all is correct, record the time of delivery and calculate the lead time. If the delivery or quality is not correct, reject the whole delivery and record reasons on the “Order log sheet”. For repeat delivery or quality problems, express your displeasure to the Production Control person. If this does not work, elevate your concerns to the Plant Manager. Notes A delivery with the correct product type and quantity received within a minute of placing the order is considered “on time”. Deliveries must be received in the sequence in which they were ordered. Deliveries received out of sequence are to be rejected. Good quality is a full nano dot with no visible damage. If any damaged or missing (blank square) nano dots are found, the whole order is rejected. Do not communicate these requirements to your supplier unless directly asked. Product type die – coloured dots on the die indicate the product type. Change the product mix for each round, e.g. R1 2G2B2R, R2 1G3B2R, R3 2G1B3R, R4 3G2B1R (each combination must have at least one of the three product colours). Quantity die – use white dots with the following numbers for each round R1 – 4X50, 1X75, 1X25; R2 – same as round 1; R3 – 40, 45, 50, 50, 55, 60; R4 – Quantity dice not used. 1 of 1 Customer work instructions

13. Customer order log sheet Round No. ______

14. Raw materials warehouse

15. Purpose As the warehouse store person, you store the raw materials and fill orders from Production Control. Materials Circuit boards Nano dots – 3 types: Green CO2, Blue H2O, Red E. Procedures Receive the customer order from Production Control. Pick the required raw materials for the order. Contact the Material Handler and ask them to deliver the raw materials to the start of production (Fusing). Notes Your boss is Production Control. Do not release raw materials from the warehouse without a customer order from Production Control. You provide excellent service to Future Solutions Enterprise and carry inventory a large inventory of raw materials to make sure production never runs out. 1 of 1 Warehouse work instructionsRound 1

16. Purpose As the warehouse store person, you store the raw materials and fill orders from Production Control. To reduce wasted motion by operators, you have implemented point of use storage at the Fusing operation for nano dots and circuit boards. As circuit boards take up a lot of space, you have determined that you will keep only 5 at the Fusers’ workstation. These will be replenished as used. To reduce waste in the Cutting operation, the supplier of the circuit boards has been requested to supply the grid area only, without the waste around the edges. Materials Circuit boards Nano dots – 3 types: Green CO2, Blue H2O, Red E. Paper cutter. 2 laminated point of use storage locators for circuit boards. 2 laminated point of use storage locators for nano dots Masking tape. Procedures Set up prior to start of round Cut out the grids on the circuit boards and dispose of the waste around the edges so that only the usable grid is supplied. Layout laminated sheets for point of use storage locations at the Fusers’ workstation (secure with tape). Fill the point of use storage locations with materials. During the round Prepare more cut out circuit boards as required. Monitor usage of the circuit boards and replenish as required (keeping the inventory at point of use to 5). Work with the material handler to make sure the Fusers do not run out of raw materials. Notes The material handler will deliver the circuit boards to the Fusers. 1 of 1 Warehouse work instructionsRound 3

17. Fuser 1 - storage area for circuit boards (R3) Max 5

18. Fuser 1 - storage area for nano dots

19. Fuser 2 - storage area for circuit boards (R3) Max 5

20. Fuser 2 - storage area for nano dots

21. Purpose As the warehouse store person, you store the raw materials and fill orders from Production Control. The point of use storage and replenishment system is the same as used in round 3. The Fusing and Laser Cutting processes have been improved to incorporate continuous flow. The supplier of the circuit boards has made a change to supply these in single strips of 10. Materials Circuit boards Nano dots – 3 types: Green CO2, Blue H2O, Red E. Paper cutter. 2 laminated point of use storage locators for circuit boards. 2 laminated point of use storage locators for nano dots (same as round 3). Masking tape. Procedures Set up prior to start of round Cut up 20 sheets into single strips of 10 squares using the paper cutter. Provide the boxes of nano dots and 10 strips to the Fusers (5 each). During the round Monitor usage of the strips and replenish as required (keeping the inventory at point of use to 5 per Fuser). Work with the material handler to make sure the Fusers do not run out of raw materials. Notes The material handler will deliver the circuit boards to the Fusers. 1 of 1 Warehouse work instructionsRound 4

22. Fuser 1 - storage area for circuit boards (R4) Max 1 strip Max 1 strip Max 1 strip Max 1 strip Max 1 strip

23. Fuser 2 - storage area for circuit boards (R4) Max 1 strip Max 1 strip Max 1 strip Max 1 strip Max 1 strip

24. Production Controller

25. Prod. Cont. order log sheet Round No. ______

26. Purpose As the Production Controller, you will schedule production of orders through the factory. You are also responsible for ordering raw materials from the supplier and delivering them to production. Materials Post-it notes and pen for recording orders. Prod. Cont. order log sheet. Procedures Receive the order from the customer. Record the order (Order no, type, quantity) on a post it note and the Prod Cont order log sheet. Give the order to the warehouse to deliver raw materials required to start of production. Monitor the progress of the order to make sure the order remains with the work as it progress through the factory so that the complete order is delivered to the customer in the correct sequence. Record details on the Prod Cont order log sheet. Notes The warehouse store person and the material handler work for you. Production control delivers and monitors orders but does not move materials (ie circuit boards, nano dots or work in progress). This is the job of the material handler. Production control is the first point of contact for the customer for delivery or quality issues. Work with the production people and support people to help resolve any issues. 1 of 1 Production controller work instructionsRound 1

27. Purpose As the Production Controller, you have worked with the production people to establish kanban pull systems. To ensure supply, you have installed point of use storage for raw materials and a kanban system with the Supplier. Materials Laminated product storage locations: 3 between Fusing and Laser Cutting; 3 finished product storage Procedures Set up of kanban systems Prior to the start of round 3, set up the kanban system by placing the WIP storage templates between Fusing and Cutting and the FG storage template after Laser Cutting. During the round Monitor the inventory levels. No need to record production orders. 1 of 1 Production controller work instructionsRound 3

28. WIP storage after Fusing (R3) Max 2

29. WIP storage after Fusing (R3) Max 2

30. WIP storage after Fusing (R3) Max 2

31. Finished goods storage (R3) FIFO flow 20 10 30 50 40 60 5 per square

32. Finished goods storage (R3) FIFO flow 20 10 30 50 40 60 5 per square

33. Finished goods storage (R3) FIFO flow 20 10 30 50 40 60 5 per square

34. Purpose As the Production Controller, you have worked with the production people to establish kanban pull systems. To ensure supply, you have installed point of use storage for raw materials and a kanban system with the Supplier. Materials 1 laminated finished product storage location. Procedures Set up of kanban systems Prior to the start of round 4, set up the kanban system by placing the FG storage template after Laser Cutting. During the round Monitor the inventory levels. No need to record production orders. 1 of 1 Production controller work instructionsRound 4

35. Finished goods storage (R4) Max 1 Max 1 Max 1 Max 1 Max 1 Max 1

36. Fusers

37. Purpose To fuse the nano dots to the circuit boards Materials Circuit boards & nano dots 2 orange changeover timers 2 downtime dice Procedures The circuit boards and nano dots required for each order are delivered by the material handlers. Place the nano dots on the circuit boards in the configuration shown below. When the order is complete, notify the material handler to collect the order. When changing between different products, turn over the orange changeover timer, wait for the changeover to take place (when the sand runs out), then proceed with production. When every 3rd order is received, before starting production, roll the downtime dice and take the action below depending on what number is rolled: Equipment failure – call maintenance and tell them you need a 1/8” X 3/4” nut & bolt. Wait till received. You are concerned about running out of parts in the warehouse. Go and question the store person. Equipment failure – call maintenance and tell them you need a 3/16” X 1/2” nut & bolt. Wait till received. You are concerned about what you will have to run for the rest of the round. Go and question Prod. Control Equipment failure – call maintenance and tell them you need a 1/4” lock washer. Wait till received. Go and ask the Plant manager how the current round of wage bargaining is going. Notes Prepare the orders in the sequence they are received. 1 of 1 Fusers’ work instructionsRound 1 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X H2O E CO2 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

38. 1 of 1 Fusers’ work instructionsRound 3

39. 1 of 1 Fusers’ work instructionsRound 4

40. Laser Cutters

41. Purpose To laser cut out the individual squares. Materials Circuit boards with nano dots Laser scissors 2 black changeover timers 2 downtime dice Procedures The circuit boards with nano dots required for each order are delivered by the material handlers. Cut the circuit boards into individual squares. When the order is complete, notify the material handler to collect the order. When changing between different products, turn over the black changeover timer, wait for the changeover to take place (when the sand runs out), then proceed with production. When every 5th order is received, before starting production, roll the downtime dice and take the action below depending on what number is rolled: Equipment failure – call maintenance and tell them you need a 1/4” X 3/4” nut & bolt. Wait till received. You are concerned about running out of parts in the warehouse. Go and question the store person. Equipment failure – call maintenance and tell them you need a 3/16” X 3/4” nut & bolt. Wait till received. You are concerned about what you will have to run for the rest of the round. Go and question Prod. Control Equipment failure – call maintenance and tell them you need a 1/4” flat washer. Wait till received. Go and ask the Plant manager how the current round of wage bargaining is going. Notes Be careful – the laser scissors are sharp! Prepare the orders in the sequence they are received. 1 of 1 Laser Cutters’ work instructionsRound 1

42. 1 of 1 Laser Cutters’ work instructionsRound 3

43. 1 of 1 Laser Cutters’ work instructionsRound 4

44. Sorters

45. Purpose To sort the final product from the waste material. To inspect the final product to ensure it is good quality. Materials Nano dot squares and blank squares. Procedures The nano dot squares and blank squares for each order are delivered by the material handlers. Sort the squares into two piles – ones with nano dots and blanks. Discard the blanks. Inspect the ones with nano dots to ensure good quality. When the order is complete, notify the material handler to collect the order. Notes Prepare the orders in the sequence they are received. 1 of 1 Sorters’ work instructionsRound 1

46. 1 of 1 Sorters’ work instructionsRound 3

47. Material Handlers

48. Purpose To move material through the factory Procedures Transport materials (steps 2 – 6) as directed by staff. Collect orders from production control and deliver to the warehouse. Collect circuit boards and nano dots from the warehouse and deliver to the Fusing workstation. Collect circuit boards with nano dots from the Fusing workstation to the Laser Cutting workstation. Collect the cut squares from the Laser Cutting workstation to the Sorting workstation. Collect the finished nano dot squares from the Sorting Station to the Shipping location. Notes Only material handlers are to move material through the factory. Priorities are set by who screams the loudest. 1 of 1 Material handlers’ work instructions 1Round 1

49. Purpose To move material through the factory Procedures Transport materials (steps 2 – 6) as directed by staff. Collect orders from production control and deliver to the warehouse. Collect circuit boards and nano dots from the warehouse and deliver to the Fusing workstation. Collect circuit boards with nano dots from the Fusing workstation to the Laser Cutting workstation. Collect the cut squares from the Laser Cutting workstation to the Sorting workstation. Collect the finished nano dot squares from the Sorting Station to the Shipping location. Notes Only material handlers are to move material through the factory. Priorities are set by who screams the loudest. 1 of 1 Material handlers’ work instructions 2Round 1

50. Purpose To ensure that the Fusers do not run out of raw material. Procedures Work with the warehouse to replenish the point of use storage at the Fusing workstation. 1 of 1 Material handlers’ work instructionsRound 3 & 4