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08/20/2007 09:52 AM
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I am looking for good games to teach aspects of Lean to students , as well as professionals.
In "good" I mean not to complex or long (max. half a day), and a really short learning curve. I already know and use the Buckingham game (with Lego's) from prof. Bicheno, but I am interesting in other games, for other aspects than teaching pull/kanban.
Rik Van Landeghem
IE professor
Ghent, Belgium
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08/21/2007 10:04 AM
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Most business people, especially senior managements, assume they are compentent and accurate observers of the business process. Step one is to shatter that assumption and rid them of their perceptual paradigms.
Short but effective game that creates a cognitive foundation, demonstrates the complexity in a process, difficulty in observing and accurately communicating those observations.
Materials:
- 8.5" by 11" pieces of paper {and bandages for paper cuts}. Writing instruments and material to write upon.
Process (Individually or in small groups):
Fold the paper to make a paper airplane. Test the airplane. All designs are acceptable. Must glide straight and level at least one foot!
Write out the process steps required to manufacture the paper airplane.
Share the processes.
Conclusion:
Are the process steps complete? Is the descriptive language consistent? Do any differences and/or standards across groups/individuals emerge? What is the value of this exercise?
Reinforce the diversity in our individual observations with a visit to Google "Optical Illusions"; compare and contrast the different perceptions. (A Classic is the young/old woman test.)
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09/05/2007 09:17 AM
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Hello,
there are a couple of games that visualize what lies behind the meaning of "LEAN". In general "LEAN" is counterintuitive, as you make more and better products with less hast, fewer people, fewer machines, etc. That doesn't mean downsizing in cutting "heads" is state of the art.
Games are then a good way to show people what "LEAN" means in reality -game and shopfloor.
Good games -from my point of view- that I have mostly already played with friends and colleagues are:
1. The Beergame
Invented at the MIT Sloan Management School, in the 60's and intensively used by Prof. John D. Sterman, Head of the System Dynamics Group at the MIT Sloan School of Management. It shows how the system is responsible for the behavior of the actors in the game. The main goal is to handle a supply chain (concerning beer) with the lowest overall process costs (inventory and backlog are costs) as a team.
It shows some very important requirements of sustainable lean implementation:
- TRUST
- COMMUNICATION
- FOCUS on the SYSTEM
Further information can be found at:
- http://web.mit.edu/jsterman/www/SDG/MFS/beerMFS.html
- http://www.beergame.lim.ethz.ch/ (online-version)
- http://www.public.asu.edu/~kir...sysdyn/BGame/BGame.htm
- http://www.pom.edu/beer/ (online version)
- http://www.sptimes.com/2007/03...uch_to_brew_Ask_.shtml (article)
2. The Airplane Game (building a paper airplane)
On request I will send you a complete description.
3. The Systems Thinking Playbook (Linda Booth Sweeney, Dennis Meadows)
Contains great short games covering the systems thinking view (essential to LEAN as well):
- Seeing the whole picture
- Changes perspectives to see new leverage points in complex systems
- Looks for interdependencies
- Considers how mental models create our future
- Pays attention and gives voice to the long-run
- "Goes wide" to see complex cause and effect relationships
- Finds where unanticipated consequences emerge
You will find the book at Amazon, ISBN 0-9666127-7-9, 75$ (rather expensive, but worth it:-))
4. Dice Game and Job Shop Game (as mentioned by Thorsten Ahrens, at http://www.openbc.com/net/lean)
http://www.vancouver.wsu.edu/f...530/Docs/DiceGames.htm (Dice Game)
http://www.vancouver.wsu.edu/f...0/Docs/JSGStudInfo.htm (Job Shop Game)
5. The Manufacturing Game
http://www.manufacturinggame.com/
6. Lego Game (Video taken during a workshop at Santech)
http://www.santech.com/game/
I hope that the hints and links are not overwhelming (and perhaps muda;-)) you.
Quite positive that there is more learning around on lean thinking, let's put the knowledge together.
Best regards
Ralf
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09/05/2007 09:17 AM
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See the attached paper plane exercise outlining the steps involved in conducting this exercise. It still needs a little fine tuning so I'd appreciate feedback. The Toast Kaizen Video is also a very good way to demonstrate Lean principles. See www.gbmp.org
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09/17/2007 04:31 PM
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Hello,
last weekend I met with some enthusiastic lean thinkers at my former university in Dresden, Germany.
We started the meeting with the Beergame and guess what? We played, analyzed and improved it during the complete day (from 10am to 6:30pm).
There is so much to do around the initial purpose of the Beergame itself (eg. communication, accounting, flow, pull, supermarkets, flexibility, etc.). It was just amazing.
If you need further information please send me an PM.
Best regards
Ralf
PS.: See also my earlier posting.
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09/20/2007 09:37 AM
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Thanks for the info so far. We have looked into some of them, and may adopt a couple. Re the beer game, we have extended it into a dual retailer version , and a variant with centralized information, on behalf of a telecom company.
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06/19/2008 08:43 AM
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Could always try the bowl game mentioned in "The goal" by Eliyahu M. Goldratt. All you need is bowls, matchsticks and dice.
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06/26/2008 01:10 PM
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I use Lego cars to teach the importance of Standard Work and Standard Operating Procedures.
The cars I choose are the smallest available (~£2.99 in the UK):
Hand each team (4-6) people a fully assembled car
They must develop assembly instructions for assembling the car from no less than 10components
Hand each team a few Standard Work sheets (SOPs) telling them they can use them in any way they choose or not at all
Remind them of the other aspects of Lean such as Visual Management, and Poka Yoke
If they ask tell them that they can use any form of technology to help learning
They must return to the classroom with the car in component form and laid out as they see fit
Get volunteers (as many as there teams) who are not part of the class, but keep them away while the teams are developing their SOPs
Introduce the volunteers as some of the World's greatest Design for Manufacturing gurus who have come to evaluate their SOPs
I allow about two minutes of "coaching time" so the teams can coach their experts
The winning team is the one which has developed the quickest and flawless assembly instructions
At the end of the exercise ask each volunteer what they liked what could be improved
Ask each team what they would do differently next time
Enjoy!
I would like to introduce elements of Safety and Error Proofing, but I'm still thinking about them. The time allowed where I teach this is about 60-90 minutes, so there is no room for a second round.
I hope this helps.
Regards,
Owen Berkeley-Hill
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08/18/2008 04:11 PM
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Here are a few things you can do if you want to stress 5S and the importance of a neat and organized work area and facility:
*Grab one of those stackable bins (any size and any color) and fill it up with random parts and items (tools, paper clips, rubber bands, pens -- whatever you can collect to make it look messy).
*Make a shadowboard for tools. Outline each tool with marker (I used a silver Sharpie on 1' x 1' pegboard). Label each tool on the shadowboard for identification purposes
*Make sure that you have two sets of the tools so that the bin and the shadowboard contain the same tools. For instance, use five different wrenches, but make sure you have two sets of them (one set to toss in the bin and one set to organize on the shadowboard).
When you complete these tasks, you can establish a game in which you can time individuals on how long it takes them to look for a specific tool in the messy bin. In contrast, you can time them on how long it takes for them to find the same tool on the shadowboard that is labeled and outlined.
If you want to really "trick" the players, you can remove tools and tell them to look for something that is not in the bin. They'll realize that they've wasted precious time searching for a tool that is probably in another bin (in the figurative sense, of course). In addition to that you can remove a tool from the shadowboard and the players will notice instantly that a tool is missing. You can also rearrange tools on the shadowboard and ask the players to find out if there is anything wrong with the organization.
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09/05/2008 12:41 PM
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Hello Rik,
I have looked for good learning exercises got frustrated. The good ones were really expensive, somewhat inflexible and not very mobile. So finally I made my own. They cover not only pull/kanban but balancing, process impropvements using fixturing to make the process more robust, cell design, designing a materials handling loop, product mix leveling and in total 10 exercises or if you apply a little imagination as many as you would like. There is a full set of instructions and all you need including data sheets and even some markers for labeling kanban cards and containers.
In the spirit of full disclosure, they are for sale on my website.
I made them, not to sell, but to use in my business...they work.
Check it out
Lonnie Wilson
www.qc-ep.com
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09/16/2008 01:20 PM
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Good afternoon:
In passing, someone referenced a short but fun exercise involving banana splits to illustrate the power of single piece flow. Has anyone worked with this?
I too am being asked to speak to students and want to make our time together as interactive and fun, yet meaningful as possible. I would love to use something similar.
Any insight is appreciated.
Ruth A. Solinski
rsolinski@niupnorth.org
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10/15/2008 10:18 PM
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Hi everybody,
Anybody interested in further info on the Beergame or the Airplane Game (actually there are several versions around; up to six) please send me personal message to ralf_lippold@web.de.
I love to learn how to combine games even further into the lean turnarounds we are all actively working on.
Best regards
Ralf
PS.: Anybody interested in further games in action please check out http://www.thirdlttleipzig.pbwiki.com
Edited: 10/15/2008 at 10:18 PM by Lean Moderator
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10/17/2008 03:24 PM
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Ruth,
Did you get any more information regarding the banana split exercise? If so, please enlighten me. It sounds like a fun teaching tool.
thanks,
stephanie.buck@dorner.com
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11/05/2008 09:27 PM
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Bruce DeWater
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There is a really good illustration of standardized work called the standard pig. Tell evryone to draw a pig, give it a name and then to show it to everyone in the group. Then bring out the set of work instructions that illustrate on numbered grid paper exactly how the pig should be drawn. at the end everyone's pig will be exactly the same, instead of the vastly different pigs that were created without instruction. Standard work brings standard results, a very fun tool to illustrate that point. I can send anyone the powerpoint slides if interested.
bdewater@charter.net
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11/14/2008 08:55 AM
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If you are looking for some lean simulations, you could take a look at my website http://www.implement-lean-manufacturing.com.
I developed a series of presentations and simulations or games that teach various aspects of lean.
For teaching the seven wastes you could simulate making coffee for example.
To teach mass production vs. one-piece flow or value stream mapping there is a lean lego simulation.
Poka yoke simulation offers another opportunity to teach this aspect of lean.
I am very interested in teaching by doing or "playing" when it's not feasible to work on a real life example.
After all, Training Within Industry demonstrated without a doubt (and Toyota adopted their methodology) that showing rather than telling has much more powerful results.
gabriela@implement-lean-manufacturing.com
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11/20/2008 09:17 PM
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Hi Every body
I have played KANBAN games in AUTOLIV : Beer Game, Lego Game and others...
It's a good method to understand the main principles
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11/23/2008 08:05 PM
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This is Radha,
I am doing my Masters in Industrial Engineering, NITIE, India.
In the book "Implementing Lean Manufacturing Techniques" by Julian Page, there are some games which teach LEAN concepts.
Games like, Ball Passing Game, Golf Ball Game, Bristle Block Game are given in the appendix of the book.
These games can teach LEAN in a practical way.... :)
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01/20/2009 09:11 AM
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Hi everybody
I've been googling "the buckingham lean game" but without any good succes.
Can anybody tell med where I can buy it, and if its any good for office/admininstrative services?
Best regards
David, Denmark
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01/25/2009 01:06 AM
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David,
John Bicheno's site is http://www.picsie.co.uk/shop/ where you will find the information you need to order the game.
Enjoy!
Owen Berkeley-Hill
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01/25/2009 03:19 PM
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Hi Gabriella,
Do you know any especificy game to transportation operation?
Anderson Santos
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