The Lean Training Game Exchange

The Training Game Exchange

Profero, Inc. | Leaders in Lean Enterprise
The Training Game
Exchange
Session D3
Monday, March 8, 2010
3:30 pm – 4: 30 pm

Profero, Inc.
9270 Corsair Road
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078
Fax: 312.294.9911
www.proferoinc.com

© Profero, Inc. 2008

Learning Outcomes
• Learn new training tools.
• Network with other trainers.
• Get ideas on how to create training
exercises for your organization.
• Please fill out the feedback forms for each
training game


© Profero, inc. 2010 1


Learning Games
• 5S – 5S Numbers Game
• Visual – Hide & Seek
• Batch Size Reduction – Index Card
Exercise
• Continuous Improvement & Flow – Tennis
Ball Exercise
• Others…


Let’s Go!
• This session is geared for the trainer
• A lot to cover in a short time – we’ll move
pretty fast and might not cover the entire
exercise
• We’ll cover the background and items
needed
• Think of this as guidelines, adapt it to your
needs. There is a lot of flexibility with
these exercises.
• Have FUN!!!




The 5S Numbers Game

A fun and exciting way to present
the 5S concepts to your team!

Profero, Inc.
9270 Corsair Road
Suite 18
Credits
This exercise is based on an exercise from www.superteams.com which was
Frankfort, IL 60423
adapted from one created by Kirt Tassmer of Stanley Fastening Systems.
Tel: 312.718.0078 The original game was developed by RWD Technologies, Ltd.D
Fax: 312.294.9911 Disclaimer
This is for entertainment purposes only. 5S Supply is not liable for any unintended outcomes.
www.proferoinc.com


Background
• This is a simple training game you can use
to show how to perform 5S and to drive
home important key points
• Number of participants: any
• Time: 30 minutes




Items
• Forms
– Overall Score and Rounds 1-5 for each
participant
• Timer
• Pens or pencils for each participant
• PowerPoint (optional)


Agenda
• Before State – Round 1
• Sort – Round 2
• Set-in-Order – Round 3
• Shine
• Standardize
• Sustain – Round 4
• Benefits – Round 5




Instructions – Round 1
• Please wait until you hear the entire
instructions before starting – DO NOT turn
over the page until asked to do so
• Individually, with a pen or pencil locate
and strike out the numbers 1 through 50 in
sequential order (1, 2, 3, 4, 5…)
• You will have 30 seconds to complete this
task


2
23 3 88 6
3 92 713 884
19
5
5

14 17
97 65
12
34
11 62
22

32 15
21 22 24 25
64 82 28 95
43 58 98 41
39

99
93

96 6
7
90
54 31 35 100
26 47
38
50
GO! 18
29

53 45 49

5 51 73
83 9 56 57 59 30
91
66
55

75
33
37 61 63
68
6
70
44
40

86
6 10 76 78
39

71 77 79
81 1 6
Profero, Inc. 1 46
20 48 89
9270 Corsair Road
72
4 85
Suite 18
74
80 60
Frankfort, IL 60423
Tel: 312.718.0078 27 94 87 42
Fax: 312.294.9911
www.proferoinc.com




Report Out – Round 1
• Record your highest number found and a
comment on your Overall Scorecard sheet
• The instructor will ask for your score – the
lowest score is what’s recorded for the
entire group
• What was it like trying to do this? How did
it feel?
• How can we apply this to everyday life?


Were there Profero, Inc. | Leaders in Lean Enterprise
any quality issues?
2
Is this3 8, 8 4, 84??? 3 884
23 an 888,
3 92 71 6
19
5
5

14 17
97 65
12
34
11 62
22

32 15
21 22 24 25
Why is839 28
64 2 95
43 58 98 41
39

99
93

96 6
7
Which one is 53
90
54 31 35 100
listed
26
twice? 47
38
50
29

45 49

56 8
the 51 and which
73
9 56 59 30
3 91
57
18
66
55

37 is61 9? 5
33
one the 7 63
68
6
70
44
40

86
6 10 76 77 78
39

71
Is this 66 or 79
81 1 6
Profero, Inc. 1 46
20 48 89
9270 Corsair Road
72
99? 89 or 68?
4 85
Suite 18
74
80 60
Frankfort, IL 60423
Tel: 312.718.0078 27 94 87 42
Fax: 312.294.9911
www.proferoinc.com




Sort
• To sort through, to sort out
• Guideline: If it is not needed in the next 30 days,
Red Tag it
• “When in doubt, move it out!”
• 5S Red Tag Technique
• Place a Red Tag on the item and move it to the
5S Red Tag Holding Area
• Items will be dispositioned: keep, throw out,
donate, scrap, shred, recycle, etc.


2
23 3 88 6
3 92 713 884
19
5
5

numbers 62 17
Let’s red tag the14 65
97
12
34
22

32 11
we don’t need (51-100) 64 82
15
21 22 24 25 28 95
43 58 98 41
39

99
and the duplicate 39. 100
93

96 6
7
35 90
54 31 26 47
38
50
29

53 45 49

5 51 73
83 9 56 59 30
91
57
18
66
55

75
33
37 61 63
68
6
70
44
40

86
6 10 76 78
39

71 77 79
81 1 6
Profero, Inc. 1 46
20 48 89
9270 Corsair Road
72
4 85
Suite 18
74
80 60
Frankfort, IL 60423
Tel: 312.718.0078 27 94 87 42
Fax: 312.294.9911
www.proferoinc.com




2
23 3 88 6
3 92 7 13 884
19

5
5
14 17
97 65
12
34
11 62

22
32 15
21 22 24 25
64 82 28 95
43 58 98 41

39
99
9

93
96 6
7
90
54 31 35 100
26 47
38
50
29

53 45 49
5 51 73
83 9 56 59 30
91
57
18
66

55
75
33
37 61 63
68
68
70
44
40

86
6 10 76 78

39
71 77 79
81 1 6
Profero, Inc. 1 46
20 48 89
9270 Corsair Road
72
4 85
Suite 18
74
80 60
Frankfort, IL 60423
Tel: 312.718.0078 27 94 87 42
Fax: 312.294.9911
www.proferoinc.com


2
23 3 88 6
3 92 7 13 884
19
5
5

Now let’s move them to the2 17
14 65
97
12
34
22

32
5S Red Tag Holding 25
11 6 2
Area.
15
2 1
22 24
64 8 28 95
43 58 98 41
39

99
93

96 6
7
35 10090
54 31 26 47
38
50
29

53 45 49

5 51 73
83 9 56 59 30
91
57
18
66
55

75
33
37 61 63
68
6
70
44
40

86
6 10 76 78
39

71 77 79
81 1 6
Profero, Inc. 1 46
20 48 89
9270 Corsair Road
72
4 85
Suite 18
74
80 60
Frankfort, IL 60423
Tel: 312.718.0078 27 94 87 42
Fax: 312.294.9911
www.proferoinc.com




2
23 3 88 6
3 92 7 13 884
19

5
5
14 17
97 65
12
34
11 62

22
32 15
21 22 24 25
64 82 28 95
43 58 98 41

39
99
9

93
96 6
7
90
54 31 35 100
26 47
38
50
29

53 45 49
5 51 73
83 9 56 59 30
91
57
18
66

55
75
33
37 61 63
68
68
70
44
40

86
6 10 76 77 78

39
71 79
81 1 6
Profero, Inc. 1 46
20 48 89
9270 Corsair Road
72
4 85
Suite 18
74
80 60
Frankfort, IL 60423
Tel: 312.718.0078 27 94 87 42
Fax: 312.294.9911
www.proferoinc.com


2
23 3 36 7 13 8
12
34 14 17 19
32 11 15
21 22 24 25 28
43
35 41
31
38

26 47
50
29

45 49

5 9 30
33 18
37
44
40
6 10
39

48
16
Profero, Inc. 1 46
9270 Corsair Road 20

4
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078 27 42
Fax: 312.294.9911
www.proferoinc.com




• Let’s do the same exercise with the
unneeded items removed from the work
area - with a pen or pencil locate and
strike out the numbers 1 through 50 in
task


2
23 3 36 713 8
12
34 14 17 19
32 11 15
21 22 24 25 28
43
35 41
31
38

26 47
50
GO! 18
29

45 49

5 9
33
30
37
44
40
6 10
39

48
16
Profero, Inc. 1 46

4
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078 27 42
Fax: 312.294.9911
www.proferoinc.com




• The lowest score is what’s recorded for
the entire group
• What was the exercise like this time?
• What can we learn from this?


Set-in-Order
• Now that the area has been cleared out of
unnecessary items, it is time to find a “home” for
items that will remain
• Guideline: Any item that you want to keep after
the 5S Red Tagging Event needs to have a
specific home
• “A place for everything and everything in its
place.”
• Organize items to make them convenient to get
and put away
• Use visual controls to help this process (signs,
lines, labels, color-coding)



2
23 3 36 7 13 8
Let’s rearrange the numbers 17
14 19
11 in
12
34
32 15
order 1 22 we will use them.
2 that 24 25 28
43
35 41
31
38

26 47
50
29

45 49
5 9 30
33 18
37
44
40
6 10

39
48
16
Profero, Inc. 1 46

4
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078 27 42
Fax: 312.294.9911
www.proferoinc.com


2
23 3 36 7 13 8
12
34 14 17 19
32 11 15
21 22 24 25 28
43
35 41
31
38

26 47
50
29

45 49

5 9 30
33 18
37
44
40
6 10
39

48
16
Profero, Inc. 1 46

4
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078 27 42
Fax: 312.294.9911
www.proferoinc.com




1
2
3 4 5 6 7 8 9 10

19
16
11 12 13 14 15 17 18 20

21 22
23 26 27 28

29
24 25
30 31 32 3433 35 3
6 37 40
44 45
38
43
41 42

39
Profero, Inc. 46
48 49
7
9270 Corsair Road
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078
4 50
Fax: 312.294.9911
www.proferoinc.com


2
1
3 4 5 6 7 8 9 10

Did you notice that we had to work
around a few things like the
13 14 15 19
16
11 12
17
numbers that were already there? 18 20

21 22
23 27 28 26
29

24 25
30 31 32 3433 35 3
6 37 40
44 45
38
43
41 42
39

Profero, Inc. 46
48 49
7
9270 Corsair Road
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078
4 50
Fax: 312.294.9911
www.proferoinc.com




• Let’s do the same exercise with the
numbers better organized - with a pen or
pencil locate and strike out the numbers 1
through 50 in sequential order (1, 2, 3, 4,
5…)
task


2
1
3 4 5 6 7 8 9 10

19
16
11 12 13 14 15 17 18 20

26 27
21 22
23
GO! 28
29

24 25
30 31 32 3433 35 3
6 37 40
44 45
38
43
41 42
39

Profero, Inc. 46
48 49
7
9270 Corsair Road
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078
4 50
Fax: 312.294.9911
www.proferoinc.com




the entire group
• What benefits can you see from “Sort” and
“Set-in-Order”?
• Record on Scorecard sheet


Shine
• Now that the area has been cleared out of
unnecessary items, it is time to “shine” the
items that remain
• Guideline: Get items to a “like-new” condition
• “Clean and inspect or inspect through
cleaning”
• Everyone participates, make it simple and
easy to get cleaning supplies and schedule it!
• If you find something out that may become an
issue, fix it or have it fixed




1
2
3 4 5 6 7 8 9 10

For Shine we will make sure the
numbers are in good working
13 14 15 19
16
11 So let’s clean this mess up! 18
order.
12
17 20

21 22
23 27 28 26

29
24 25
30 31 32 3433 35 3
6 37 40
44 45
38
43
41 42

39
Profero, Inc. 46
48 49
7
9270 Corsair Road
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078
4 50
Fax: 312.294.9911
www.proferoinc.com


1
2 3 4 5 6 7 8 9 10

11 12
13 14 15 16 17 18 19 20

21 22
23 24 25 26 27 28 29 30

31 32 33 34 35 36 37 38 39 40

Profero, Inc.
9270 Corsair Road

41 44 47 48 50
Suite 18
42
Frankfort, IL 60423 43 45 46 49
Tel: 312.718.0078
Fax: 312.294.9911
www.proferoinc.com




Standardize
• We need to have standards for the first
three S’s: Sort, Set-in-Order and Shine
• Guideline: Make up the rules for the first
three S’s and then follow and enforce
them.
• “Make up the rules and then follow them”
• Don’t forget to consider companywide
policies like color-coding, signage,
replenishment, etc
• Make the rules easy to follow

1
2 3 4
5 6 7 8 9 10
After looking at all the styles of
font and sizes the team determined
13 14 15 16 17
that some of these items can be 18
11 12
19 20
standardized.
21 22
23
24 25 27 28 29 30 26
31 32 33 34 35 36 37 38 39 40

Profero, Inc.
9270 Corsair Road

41 44 47 48 50
Suite 18
42
Frankfort, IL 60423 43 45 46 49
Tel: 312.718.0078
Fax: 312.294.9911
www.proferoinc.com




1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 49 50

Profero, Inc.
9270 Corsair Road
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078
Fax: 312.294.9911
www.proferoinc.com


1 2 3 4 5 6 7 8 9 10
Let’s add 13 14 more visuals like
11 12 some 15 16 17 18 19 20
color-coding and lines.
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 49 50

Profero, Inc.
9270 Corsair Road
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078
Fax: 312.294.9911
www.proferoinc.com




1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 49 50

Profero, Inc.
9270 Corsair Road
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078
Fax: 312.294.9911
www.proferoinc.com


Sustain
• Now that you have a well organized, clean
and safe work environment, we must keep
it that way
• Guideline: It’s not something extra, it’s part
of everyday work
• “Make 5S part of everyday life.”
• Sustain helps build the discipline we need
to have a great Lean organization




• In order to Sustain our gains we must be
able to recognize abnormal conditions
• Let’s do a quick 5S Audit of the area
• Circle any “defects” that you find
task


1 3 4 5 6 7 8 10
9
16
12 11 13 14 15 17 18 19 20

21 22 23 34 25 26 27 28 29 30
31 32 33 24 35 36 37 38 40
41 42 43 44 45 46 47 48 49 50GO!
Profero, Inc.
9270 Corsair Road
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078
Fax: 312.294.9911
www.proferoinc.com




How many did you find?
• The “2” is missing
• “9” is upside down
• 11 and 12 are mixed up
• “16” is not completely in it’s home
• 24 and 34 are in the wrong location
• “39” is missing
• 46 is askew
How did you know?

1 3 4 5 6 7 8 10
9
16
12 11 13 14 15 17 18 19 20

21 22 23 34 25 26 27 28 29 30
31 32 33 24 35 36 37 38 40
41 42 43 44 45 46 47 48 49 50

Profero, Inc.
9270 Corsair Road
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078
Fax: 312.294.9911
www.proferoinc.com




• Let’s do the same exercise after applying
our 5S principles - with a pen or pencil
strike out the numbers 1 through 50 in
task


1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 49 50GO!
Profero, Inc.
9270 Corsair Road
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078
Fax: 312.294.9911
www.proferoinc.com




the entire group
• What benefits can you see from “Sort” and
“Set-in-Order”?
• How can we apply this to everyday life?


Before & After State
Before After
• Excess materials • The correct materials
• Excessive search time • Minimal search time
• Large area • Smaller area
• Cluttered • Clean, neat &
• Difficult organized
• Easy




2
23 3 88 6
3 92 7 13 884
19

5
5
Before 14 17
97 65
12
34
11 62

22
32 15
21 22 24 25
64 82 28 95
43 58 98 41

39
99
9

93
96 6
7
90
54 31 35 100
26 47
38
50
29

53 45 49
5 51 73
83 9 56 59 30
91
57
18
66

55
75
33
37 61 63
68
68
70
44
40

86
6 10 76 78

39
71 77 79
81 1 6
Profero, Inc. 1 46
20 48 89
9270 Corsair Road
72
4 85
Suite 18
74
80 60
Frankfort, IL 60423
Tel: 312.718.0078 27 94 87 42
Fax: 312.294.9911
www.proferoinc.com


1 2 3 4 5 6 7 8 9 10
After
11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 49 50

Profero, Inc.
9270 Corsair Road
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078
Fax: 312.294.9911
www.proferoinc.com




Benefits of 5S
• What benefits did we • _________________
realize by applying 5S • _________________
to our simulated • _________________
workplace?
• _________________
• Quality
• _________________
• Cost
• _________________
• Delivery/Service
• _________________
• Quantitative
• _________________
• Qualitative
• _________________

Resource
• This game is available at :

www.5Ssupply.com

• PowerPoint
• Forms
• Video





Hide & Seek

Hurry we need this now!

Profero, Inc.
9270 Corsair Road
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078
Fax: 312.294.9911
www.proferoinc.com


Background
• Use this exercise to show the power of
visual controls
• Two versions – manufacturing & office
• Number of participants: 4-5 people per
team, 2-4 teams
• Time: 15-30 minutes




Items
• Small objects (like K’nex pieces) for
manufacturing
• File folders for office
• Timer
• Flipchart to record scores
• Colored markers, post-it notes, paper,
tape, etc to make signs


How to – Round 1
• Have one person from each team act as
the “new employee”
• Bring them out to the hallway and show
them the item need to find
• Let them know that their team is not going
to help them
• Have them wait in the hall until they are
called-in




How to – Round 1
• While the new employees wait in the hall,
explain to the teams that they need to hide the
object somewhere in the room
• Don’t make it obvious and don’t make it
impossible
• Have one person from each team act as the
timer – the time from when their employee walks
in the room until that person finds the correct
object
• That can’t help – they can only say things like
“Hurry”, We need this now!!!”
• Encourage the team to badger the new
employee

How to – Round 1

• GO!




• How did you feel?
• What was it like?

Round 1 Round 2

Team 1

Team 2

Team 3

How to – Round 2
• Have the new employees go out into the
hallway again
• Explain to them that they will do the same
thing as before – try to find the item as fast
as they can.
• Let them know it will be a few minutes, so
relax




How to – Round 2
• Have the team hide the objects again, they
choose even a harder spot this time
• This time the teams can make whatever
visuals they would like (signs, lines, labels,
color-coding, etc.) to make it easier for
their employee
• Coach them on good visuals (size,
locations, think of the user, etc.)
• Same as before – time and no helping
only badgering

How to – Round 2

• GO!




• How did you feel this time?
• What was it like?

Round 1 Round 2

Team 1

Team 2

Team 3


Index Card Game

Batch size reduction really works!

Profero, Inc.
9270 Corsair Road
Suite 18
Frankfort, IL 60423
Tel: 312.718.0078
Fax: 312.294.9911
www.proferoinc.com




Background
• Use this exercise to show how batch size
reduction reduces lead-time
• Number of participants: 4-5 people per
team, 2-3 teams
• Works best if the teams are sitting next to
each other
• Variation: Signatures or use stickers,
scissors, tape, etc.
• Time: 15-30 minutes

Items
• Colored index cards (3” x 5”) – 40 cards
per team, 4 colors x 10 cards
• Timer
• Pens or pencils for each participant
• Optional: stickers, scissors, tape, stamps




How to
• Prior to the exercise sort out the index
cards 10 of each color x 4 colors for a total
of 40 cards per team
• Based on the number of teams have:
– 1 team do the exercise in batches of 10
– 1 team in batches of 5
– 1 team in batches of 1


How to
• Explain to each person that all they have
to do is clearly print their first and last
name on the card
• When they have completed their “batch”
(10, 5, or 1) they can move that batch to
the next person
• Make sure they understand that they can’t
move it on until the “batch” is complete



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