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Lean Lego Game
I'd like to invite you on a journey where we learn by playing a lean Lego game. The idea came to me as I was getting frustrated with the high price of similar games (around $800). Personally I see no reason to pay such prices especially when lean is about saving money. The game that you can teach right away to your team costs only $25 for the instructions package. You only need to purchase a 1200-piece Mega Bloks or Lego from any department or toy store. I bought mine for $19.99. The game comes with full instructions, pictures with the operator work instructions, spreadsheet, current and future value stream map, opportunities marked on the map, all in a presentation format, ready to be delivered. There are three rounds, each round is played for 15 min (1 min equates 30 min real time). The maximum number of boats that can be built is 35, more than enough for the whole game, as each round you start from zero. The game is for 6-8 people. If you have more players, just buy another Mega Bloks or Lego game and use the same instructions. It can be seen as a competition between teams.
The Blue Sea Boat Corporation is in the boat business.They make wonderful boats, appreciated all over the world. Last week they negotiated a large contract and now they have to deliver 25 boats each day. They have a problem though as the maximum number they ever produced in one day was 10. How are they going to deliver the promise? Let’s look at their current operations. Blue Sea uses an MRP system with quarterly sales forecast. Every week schedules are sent to Operation 20 and 40. Daily they make adjustments, if necessary. The customers send their orders daily and the shipping department ships around 10 boats each day. The main supplier is Naval Supplies Company, 30 miles away. Weekly they receive purchase orders for the week ahead and monthly they get a forecast. The deliveries to Blue Sea come once a week. Customer Requirements = 25 boats/day (current 10) The plant operates 5 days a week, 240 days of the year, on a one-shift basis of 8 hours with a 20-minute lunch break and two 5-minute coffee breaks. Plant Effectiveness = 85% There are four assembly operations, one final inspection operation and a shipping operation. OP10 Assembly 1 OP20 Assembly 2 OP30 Assembly 3 OP40 Assembly 4 OP50 Assembly 5 and Final Inspection OP60 Shipping Do you want to know how they succeeded? Let's embark on the wonderful world of learning by playing and solve the mystery together.
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