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

Date order received

Time order received

Customer Signature

Customer Signature

For Official Use Only Parts Supplied from Stores Model Constructed Model pass QC

Time

Initial

Marvellous Models Inc. Order Form Model Colour

Date order submitted

Time order submitted

Date order received

Time order received

Customer Signature

Customer Signature

For Official Use Only Parts Supplied from Stores Model Constructed Model pass QC

Time

Initial

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 Ideal for those times when only a boat just isnt enough Duck Robot That perfect mechanical help around work and the home

Chair Perfect for when sitting around is the option of choice

Aeroplane Want to get somewhere, and fast? You need to fly!

Dinosaur

Horse Didnt everyone want a pony when they were young? Get yours now!

Arrrgh! Its a scary dinosaur!

Colour selection: Blue Green Purple

Yellow Orange Pink

www.st-andrews.ac.uk/lean

Marvellous Models, Inc. Construction Instructions

Aircraft carrier

Components 14 3 10

Duck Robot

Components 2 7 7

Chair

Components 16 0 12

Aeroplane

Components 0 2 5

Dinosaur

Components 10 3 4

Horse

Components 4 6

www.st-andrews.ac.uk/lean