Lean Lego Overview Marvellous Models, Inc

Lean Lego
Marvellous Models, Inc
Overview
This activity will give the participants the opportunity to:
 Participate in a process
 Evaluate the process
 Identify wastes that can be eliminated from the process
o Transport
o Inventory
o Motion
o Waiting
o Over production
o Over processing
o Defects
o Skills
 Redesign the process to eliminate wastes
 Measure time savings in redesigned process
This will allow participants to experience how Lean can be applied to
processes, and appreciate the benefits of using a Lean approach.
In this activity, there are 5 different roles:
 Stores
 Construction 1
 Construction 2
 Supervisor/Quality Control
 Customer.
Participants take on one role, and are given some guidance notes of
what is involved in that particular role.
The KPI for the supply of models to the customer is 5 minutes per
model.
www.st-andrews.ac.uk/lean
Lean Lego
Marvellous Models, Inc
Instructions: Stores
Your task is to supply the bricks as requested. Your store, consists
of hundreds of Lego bricks in different colours. When one of the
construction sites receives an order, they will come to you and ask
you to supply the bricks required. Put the bricks that they ask for
on one of the paper plates and give them to the construction team
as required. There is a form to be completed on supply. The
construction team will give this to you to fill in as appropriate and
return with the bricks.
www.st-andrews.ac.uk/lean
Lean Lego
Marvellous Models, Inc
Instructions: Customer
You have been given a supply of order forms to enable you to
request some Lego models from a catalogue. You can choose which
models you want, and pick the colours you would like them in. You
need to complete one form per model, and take the orders to the
Supervisor/Quality Control. Please note the time of your order on
the form. Once the models are complete, they will be returned to
you and you should note the time of delivery on the form.
www.st-andrews.ac.uk/lean
Lean Lego
Marvellous Models, Inc
Instructions: Construction 1
Your role is to construct the non-animal models from Lego bricks.
You will receive orders for specific models from your Supervisor.
When you receive an order, you need to visit Stores, give them the
order form and collect the right amount of bricks. You then need to
return to the building station and build the model. Completed
models should be taken to the Supervisor who will do a quality
control check.
www.st-andrews.ac.uk/lean
Lean Lego
Marvellous Models, Inc
Instructions: Construction 2
Your role is to construct the animal models from Lego bricks. You
will receive orders for specific models from your Supervisor. When
you receive an order, you need to visit Stores, give them the order
form and collect the right amount of bricks. You then need to
return to the building station and build the model using the
appropriate template you have been given. Completed models
should be taken to the Supervisor who will do a quality control
check.
www.st-andrews.ac.uk/lean
Lean Lego
Marvellous Models, Inc
Instructions: Supervisor/Quality Control
You will receive orders for Lego brick models from the Customer.
You need to check the order then pass it onto the appropriate
construction team. Construction Team 1 build the non-animal
models, and Construction Team 2 build the animal models. The
completed models will be returned to you for a Quality Control
inspection, where you will compare the model with the appropriate
template. If you are happy with the quality, then the model should
go to the Customer together with the original order form. If the
model is not correct, it should be returned to construction to fix
before passing onto the customer.
www.st-andrews.ac.uk/lean
Marvellous Models Inc. Order Form
Model
Colour
Date order
submitted
Time order
submitted
Customer Signature
Date order
received
Time order
received
Customer Signature
For Official Use Only
Parts Supplied from Stores
Time
Initial
Model Constructed
Model pass QC
Marvellous Models Inc. Order Form
Model
Colour
Date order
submitted
Time order
submitted
Customer Signature
Date order
received
Time order
received
Customer Signature
For Official Use Only
Parts Supplied from Stores
Time
Initial
Model Constructed
Model pass QC
www.st-andrews.ac.uk/lean
Marvellous Models, Inc. Product Catalogue
Please feel free to browse our catalogue below, and once you have
made your selection, complete one of our order forms.
Model selection:
Aircraft carrier
Duck Robot
Ideal for
those times
when only a
boat just
isn’t enough
That perfect
mechanical
help around
work and
the home
Chair
Aeroplane
Perfect for
when sitting
around is
the option
of choice
Want to get
somewhere,
and fast?
You need to
fly!
Dinosaur
Horse
Didn’t
everyone
want a pony
when they
were
young? Get
yours now!
Arrrgh! It’s
a scary
dinosaur!
Colour selection:
 Blue
 Green
 Purple



Yellow
Orange
Pink
www.st-andrews.ac.uk/lean
Marvellous Models, Inc. Construction Instructions
Aircraft carrier
Chair
Dinosaur
Components
Duck Robot
Components
14
2
3
7
10
7
Components
Aeroplane
Components
16
0
0
2
12
5
Components
10
3
4
Horse
Components
4
6
6
www.st-andrews.ac.uk/lean