The Numbers Game

1. The Numbers Game

2. For our first action, we are going to implement 5S in this area. • The first step of this is “Sort” and so we have removed from the area everything that is not needed. • Same rule apply. Strike out numbers 1 to 49 in sequence during a 20 second shift.

3. 48 45 30 33 27 3 21 24 18 9 6 36 15 12 42 39 2 29 5 41 20 23 35 32 44 8 26 47 17 11 38 14 31 49 34 7 28 40 16 10 22 1 43 4 25 13 37 19 46

4. Having achieved some improvement, we now need to move onto the next step ”Set In Order”. • We have installed some racking, and we have organized the items so that with Number 3 in the top right hand corner, the numbers are located from left to right and top to bottom - examples 1 in the top left, 2 in the top middle, and 3 in the top right. • Same rules apply 20 second shift, lowest individual score equals team score etc…

5. 48 45 30 33 27 3 21 24 18 9 6 36 15 12 42 39 2 29 5 41 20 23 35 32 44 8 26 47 17 11 38 14 31 49 34 7 28 40 16 10 22 1 43 4 25 13 37 19 46

6. We’re going to ignore “Shine” for this exercise. • Let’s assume for this task that we were not disciplined enough to maintain our behaviors and that we lost the gains we had made. • We will be returning to our original work area and for this assignment we have a quality problem, two numbers are missing. • We cannot complete our process without these numbers - so first we have to find them. • Start a clock running and every 20 seconds, tell them how many “shifts” they have been “down” looking for the appropriate numbers.

7. 48 87 45 72 30 33 27 3 69 51 21 24 57 9 75 54 78 6 36 63 60 15 12 81 39 84 66 90 53 2 68 80 77 86 62 74 29 65 5 41 20 23 35 56 32 89 44 8 83 50 26 47 17 11 38 71 59 14 31 64 49 34 61 7 28 54 40 16 52 58 76 10 22 88 73 85 1 43 4 82 25 13 37 19 67 79 46 70

8. Now let’s go back and assume we have the discipline to implement “Standardize”. • Since we are dealing with numbers 1 to 49 in sequence, it seems logical to re-organize them in a standard way that makes the completion of the work task as easy as possible. • This should ensure that everyone is able to complete the task (and therefore produce a team score of 49.)

9. Numbers from 1 to 49 2 10 4 7 8 6 3 5 9 1 16 20 15 17 18 11 19 14 12 13 21 24 25 27 28 22 26 30 23 29 32 31 33 36 37 34 39 38 40 35 41 47 44 43 45 49 48 42 46

10. Now how much easier is it to find the quality problems?

11. Numbers from 1 to 49 2 10 4 7 8 6 3 5 9 1 16 20 15 17 18 11 19 14 12 21 24 25 27 28 22 26 30 23 29 32 31 33 36 34 39 38 40 35 41 47 44 43 45 49 48 42 46