Michigan Lean Consortium Lean 101 Exercise Instructions Standard

Michigan Lean Consortium Lean 101 Exercise Instructions

Standard Work: Pig Exercise (facilitator) Read the initial instruction slide from the training presentation 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! 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 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, 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 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 2 , .

Standard Work

Standard Work (participants) 1. 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 2. 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 3. 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 4. 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 5. 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 6. 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 7. 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 8. 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 9. Draw a line from the top of that circle to the bottom left leg of the M which is near the top left intersection 10. Draw a line from the bottom of that circle to the top left leg of the W which is near the bottom left intersection 11. 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. 12. 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 13. 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 14. Finally, draw 2 small circles next to each other inside the large circle which is centered in the middle row, left column

Standard Work (what the pig should look like)

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 6 , .

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 7 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. 8 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) , .