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01 - Lean Six Sigma Overview

The document describes a Lean Six Sigma simulation involving folding paper airplanes. Participants take on roles in the process such as operators, a supplier, and a customer. The simulation is run in two rounds, with different rules each time, to compare performance metrics and identify areas for improvement. In the first round, airplanes are moved in batches with a focus on individual roles. In the second round, the process switches to one-piece flow controlled by kanbans with an emphasis on teamwork and customer satisfaction. Data is collected after each round to analyze changes.

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Balaji S
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56 views8 pages

01 - Lean Six Sigma Overview

The document describes a Lean Six Sigma simulation involving folding paper airplanes. Participants take on roles in the process such as operators, a supplier, and a customer. The simulation is run in two rounds, with different rules each time, to compare performance metrics and identify areas for improvement. In the first round, airplanes are moved in batches with a focus on individual roles. In the second round, the process switches to one-piece flow controlled by kanbans with an emphasis on teamwork and customer satisfaction. Data is collected after each round to analyze changes.

Uploaded by

Balaji S
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Module BB2A

Lean Six Sigma -


Paper Airplane
Simulation

Lean Six Sigma


Black Belt
The Participants

• 4 Operators
• 1 Production Supervisor
• 1 Material Handler
• 1 Raw Material Supplier
• 1 Customer
• 2 Timers
• All other class members: Wasteologists

2
Instructions

• Each operator will get instructions and practice once


• Each Operator sits at a different table in a different part of the room.
• Raw Material Supplier – Keep Operator # 1 supplied with sets of 3
• Customer – Take delivery of sets of 3 as quickly as they can make
them. Classify them as Accept or Reject in terms of quality.
• You will see a Blue airplane come through with a set of 2 White
planes. Treat it like a white one and move it in a batch of three. We’ll
stop when the customer gets the Blue Airplane.
• Timer #1 – Start your clock at the beginning and stop it when the
Customer gets the Blue Airplane – You will measure Total Time.
• Timer #2 – Start your clock when Operator #1 starts working on the
Blue Airplane and stop it when the customer gets the Blue Airplane.
You will measure Lead Time for the Blue Airplane.

3
Instructions Round 1

• We will fold and move airplanes in batches of 3


• FIFO at each Operator
• Only the Material Handler can move airplanes between
operators – When you have 3 ready, call for the Material
Handler
• Each Operator is paid a Bonus on HOW MUCH YOU
MOVE from your station.
• The Supervisor cannot touch product – but you are
responsible for Keeping the Customer Happy!
• Wasteologists – Look for Opportunities for Improvement.

BEGIN!!
4
Data Collection

The following metrics to be compiled for each round:

• Total time to complete order


• Cycle time for Blue Airplane
• WIP
• Good airplanes and rejects at customer
• Total staff count

5
End of Round One

• Wasteologists, what ideas do you have for


improvement?

• List ideas and implement changes!

6
Instructions Round 2

• The Customer wants to take delivery of 1 Airplane every 15


Seconds (Takt Time).
• Raw Material Supplier – Keep Operator #1 supplied 1 piece
at a time
• You will see a Blue Airplane come through with a set of two
White planes. Treat it just like a white one and move it in a
batch of three. We’ll stop when the customer gets the
Blue Airplane.
• Timer #1 – Start your clock at the beginning and Stop it
when the Customer gets the Blue Airplane – You will
measure Total Time.
• Timer #2 – Start your clock when Operator #1 starts working
on the Blue Airplane and stop it when the Customer gets the
Blue Airplane – You will measure Lead Time for the Blue
Airplane.
7
Rules of Round 2

• We will Fold and Move Airplanes in 1 piece flow.


• Operators will sit around a table such that they form a
counterclockwise U
• Each Operator is paid Bonus on how satisfied the
Customer is – The entire team gets the same Bonus.
• Kanbans will control Production. Use a sheet of paper with
a colored Post-It to the left of their workstation as the input
Kanban. Do not place completed work in your output
Kanban (on your right) unless the Post-It is visible.
• Stop the simulation as soon as the Customer has been
delivered the Blue Airplane.
• Calculate the Round 2 metrics and compare.

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