Lean Paper Airplane Game Grades 6 8 APICS

Lean Paper Airplane Game Grades 6 - 8 APICS Certified Supply Chain Professional™ (CSCP) Learning System © 2016 APICS Confidential and Proprietary Version 3. 3, 2015 Edition

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Today’s Objectives ▪ Create Awareness of Supply Chain ▪ Experience how Supply Chain & STEM work together ▪ Have fun! 3 © 2016 APICS Confidential and Proprietary

STEM Science Technology Engineering Math 4 © 2016 APICS Confidential and Proprietary

Supply Chain Source Make Deliver Reuse/Recycle 5 © 2016 APICS Confidential and Proprietary

Supply Chain and STEM make things happen! Supply Chain Source Make Deliver Reuse/Recycle 6 © 2016 APICS Confidential and Proprietary STEM + Science Technology Engineering Math

Mass Production ▪ Producing large amounts of standardized products in an assembly line ▪ Example: Ford’s production line ▪ Think “Lean” – do you see any ways (small or big) to improve the process? Could this process be improved? Is that how cars are made today? 7 © 2016 APICS Confidential and Proprietary

Work in Process (WIP) Unfinished products in a production process. 8 © 2016 APICS Confidential and Proprietary

Metrics Measurement of Performance or Product Quality Time Cost 9 © 2016 APICS Confidential and Proprietary

Paper Airplane Competition 10 © 2016 APICS Confidential and Proprietary

Team Setup ▪ The class should divide into teams of about 5 -7 students/team. ▪ Each team should be seated at their own table – and separated from the other teams. ▪ Ensure there is sufficient room to flight test – launching the airplanes towards a wall (away from students, and not towards other teams). ▪ Each team member starts as a design engineer. 11 © 2016 APICS Confidential and Proprietary

Game Instructions ▪ Each team member will design their own prototype plane that meets the design criteria (white paper). ▪ Each team will pick one winning prototype design. ▪ The winning design for each team will go into high volume manufacturing (HVM). ▪ Each team will make one golden image of their winning design (white paper). 12 © 2016 APICS Confidential and Proprietary Engineering Design Criteria ▪ Plane must have at least 5 folds. ▪ Plane must be able to fly at least 5 feet. Winning Design Picked & Golden Image Made in 5 Minutes

Ex: Basic Plane Model – but be creative Work 1 Work 2 Fold up in half long way. Fold first corner down on each side. Work 3 Work 4 Second fold of wing in each side. Third fold of each wing on each side. Place in finished goods inventory. 13 © 2016 APICS Confidential and Proprietary

Teams picks their winning design. 5 minutes to test, discuss and select winner 14 © 2016 APICS Confidential and Proprietary

Day 1 Recap Key Words ▪ ▪ ▪ Supply Chain – 4 Key Areas STEM Prototype Mass Production WIP Metrics Key Learnings – class inputs 15 © 2016 APICS Confidential and Proprietary

WELCOME TO DAY 2 Lean Paper Airplane Game Grades 6 - 8 16 © 2016 APICS Confidential and Proprietary

Day 1 Recap Key Words ▪ ▪ ▪ Supply Chain – 4 Key Areas STEM Prototype Mass Production WIP Metrics 17 © 2016 APICS Confidential and Proprietary

Day 2: Game Day! Today’s focus areas: 1. Assembly Line Manufacturing 2. Metrics Team Set Up ▪ Get back into your original teams ▪ Each team member will have 3 minutes to create a replica of the design win from Day 1 ▪ The “Best” replica will be reserved as the “Golden Image” for quality validation 18 © 2016 APICS Confidential and Proprietary

Group and Materials Group: ▪ 4 -6 Manufacturing Engineers ▪ 1 Quality Engineer Materials: ▪ Paper Sheets for making planes (8 ½ x 11) – Unique color paper/team recommended ▪ Pencils ▪ Scoring sheets ▪ Timer 19 © 2016 APICS Confidential and Proprietary

Round 1: How many Planes should we make? In looking at our historical data, we see that our customers have been wanting us to build more and more planes each month. Management has decided that demand is probably going to increase substantially in the month of October. We want to be sure we can meet this increased demand while making money. Each plane sells for $20. 00! To be safe, we will make as many as we can. Month Demand May 7 planes June 9 planes July 12 planes August 15 planes September 20 planes October ? 20 © 2016 APICS Confidential and Proprietary

Push Method-Round 1 Goal: make as MANY airplanes as you can. Manufacturing Engineering Team – all members must have unique roles and must repeat their step for each plane. 5 minutes! Quality Engineer ▪ Will visually inspects each plane against the Golden Image: pass/fail ▪ As soon as you finish your step pass it to the next person as quickly as possible; if they are working on another one that’s okay, set it on their workstation and keep going with your step! When the Clock has Stopped: ▪ When the plane is complete the last production engineer will give it to the quality engineer. ▪ Each plane sells for $20. 00 and the WIP cost is $5. 00/plane ▪ Quality Engineer will test passing planes and calculate team metrics. ▪ Winning Team: The most quality planes at the end of the round ▪ Have fun! 21 © 2016 APICS Confidential and Proprietary

Time to do a flight test! ▪ Move to your team’s test area ▪ Test only the planes that pass visual inspection ▪ Keep track of the # of planes that pass the 5 ft. flight test. These are “good” planes. ▪ Complete your team’s metric sheet 22 © 2016 APICS Confidential and Proprietary

Round 1: Metrics Metric Definition # Good # Planes built correctly (Flyable and pass visible inspection) % Good # good planes / total planes built Round #1 Average Lead Time time it took to build good planes / total good planes built WIP # unfinished planes Productivity # good planes / # Engineers / 5 minutes WIP cost # of unfinished planes x $5 (WIP cost/plane) Profit (# Flyable planes x Sales price) – WIP cost 23 © 2016 APICS Confidential and Proprietary Round #2

What did we observe in Round #1? ▪ ▪ Were there any problems? Did any planes build up at a certain location? (bottleneck) Were there any quality issues? How would you make the next round better? 24 © 2016 APICS Confidential and Proprietary

What is LEAN? ▪ Steps to drive process efficiency by eliminating waste Defects Transporting Overproduction Waiting Excess Inventory Excess Motion 25 © 2016 APICS Confidential and Proprietary Unused Talent Extra Processing

Lean Method-Round 2 For this round, your goal is to maximize profit without sacrificing the quality of the planes. Excess WIP is a problem – we don’t want any. Engineering Team – take two minutes to reconfigure your teams to support your “LEAN” process. ▪ There will now be a staging area to prevent overproduction. – Each person on each team will get a post-it. – You will only be allowed to produce your part of the plane when your post-it note is not covered by WIP. Quality Engineer will enforce these rules. Once time is up… Quality Engineer will inspect your planes and calculate your metrics. ▪ Sales price for each plane is $20. 00 ▪ WIP cost per unit is $5. 00. 26 © 2016 APICS Confidential and Proprietary 5 minutes!

Time to do a flight test! ▪ Go back to your test area ▪ “Good Planes” = those that can fly > 5 feet. 27 © 2016 APICS Confidential and Proprietary

Round 2: Metrics Metric Definition # Good # Planes built correctly (Flyable and pass visible inspection) % Good # good planes / total planes built Round #1 Average Lead Time time it took to build good planes / total good planes built WIP # unfinished planes Productivity # good planes / # Engineers / 5 minutes WIP cost # of unfinished planes x $5 (WIP cost/plane) Profit (# Flyable planes x Sales price) – WIP cost 28 © 2016 APICS Confidential and Proprietary Round #2

Round 2: Follow-up ▪ Which production method would you choose for your company? Why? ▪ Which team made the most profit? ▪ How did the changes we made with resource-leveling and WIP change our metrics results? ▪ How did our quality improve? ▪ Did you see any areas where STEM was involved? 29 © 2016 APICS Confidential and Proprietary

Activity Summary ▪ We learned about Supply Chain using Paper Airplanes! – Source – Make – Deliver – Reuse/Recycle ▪ We learned about Science, Technology, Engineering & Math too! – Science: Optimize your paper airplane flight distance – Technology: Mass Production of Automobiles – Engineering: Improving the production of paper airplanes (LEAN) – Math: Calculating Metrics ▪ What else did you learn today that was new? ▪ Did you have FUN? 30 © 2016 APICS Confidential and Proprietary

Please… RECYCLE ALL PAPER PLANES AFTER ROUNDS ARE FINISHED (can bring to younger students, or recycle) 31 © 2016 APICS Confidential and Proprietary

Round 1 Discussion Aide: Page 24 ▪ Positive: Cost per unit goes down as profit goes up ▪ Negative: Overproduction and excess WIP is costly and wasteful. ▪ Items to consider for additional discussion – Compare winners based on profit – Who would the winner be if each WIP cost $5? – What would happen if the customer suddenly demanded a change or a different product? ▪ What if October demand dropped to 3 planes? ▪ Who would be the winner each plane that had to be scrapped cost $5? – Does the overproduction seem wasteful if we don’t need it? – Is making the most airplanes the correct incentive for workers? – How can we better control WIP? – How does this type of process impact quality? 32 © 2016 APICS Confidential and Proprietary

Classroom Set Up Front Of Class/ Power Point Display + Whiteboard Area 5 ft. Team #2 Test Flight Wall Team #1 Test Flight Wall Team #3 Test Flight Wall 5 ft. Team #1 Team #2 Table Team #3 Team #4 Table 5 ft. 33 © 2016 APICS Confidential and Proprietary 5 ft. Team #4 Test Flight Wall

Activity Kits/Supplies List of materials Needed for 1 class of 28 students List of materials Needed for 1 team of up to 7 (4 teams of up to 7 students) students ▪ ~300 sheets of paper* (or 1 ream) ▪ ~75 sheets of paper* ▪ 4 pads of post it notes (any size) ▪ 1 pad of post it notes (any size) ▪ 4 calculators (or smart phones with calculator) ▪ 5 -10 pencils ▪ Ability to display a power point in the class ▪ 1 calculator (or smart phone with calculator) ▪ 1 -2 pencils ▪ Chalkboard & Chalk, dry erase board & markers, or flip chart + marker ▪ 1 set of 50 small lightweight stickers (stars, other) ▪ 6 metric sheet print outs – slide 36 (includes 2 spares for mistakes) ▪ 1 metric sheet – slide 36 *Use standard copier paper (lightweight) to aid in ease ▪ Optional: 4 sets of 50 small lightweight stickers of folding a flight. (stars, other) each set a unique color to add unique team customization *Nice to have a unique color paper for each time, but not required. 34 © 2016 APICS Confidential and Proprietary

Team Name__________________ Metric Definition # Good # Planes built correctly (Flyable and pass visible inspection) % Good # good planes / total planes built Average Lead Time time it took to build good planes / total good planes built WIP # unfinished planes Productivity # good planes / # Engineers / 5 minutes WIP cost # of unfinished planes x $5 (WIP cost/plane) Profit (# Flyable planes x Sales price) – WIP cost 35 © 2016 APICS Confidential and Proprietary Round #1 Round #2