The Waste Identification and Elimination exercise was created to instruct sutdents to Learn to See waste using a Flight Simulator scenario. Enjoy, Todd McCann GANBARE!

1. 7 WASTES
7 Original Wastes as prescribed by T. Ohno
Identification and Elimination
“Flight Simulator” Exercise
MUDA
1
Un-Necessary
Over Production
7 2
Corrections Un-Necessary
Inventory
6
Un-Necessary 3
Over Processing Un-Necessary
Transportation
5
Un-Necessary
4
Un-Necessary
Created by Todd McCann
Waiting Motion
A Quote from Taiichi Ohno
“ Where there is NO Standard
there can be NO KAIZEN”
We Serve the GEMBA
We Teach Leaders to “Learn to See” and “Serve the Gemba”
Recognition: This exercise was created by Todd McCann of Savant and is being shared
with others for the benefit of others to learn about waste identification and elimination.
Out of respect for the effort and work put forward to create this exercise
Please recognize prior to start of exercise

2. Work Instruction
WASTE IDENTIFICATION Production Manager Only
AND ELIMINATION
EXERCISE
BACKGROUND
The WasteFree Manufacturing Company
builds personal watercraft for the
recreational market.
Increased competition from the Far East and
Canada has squeezed margins in the last
two years.
One of the key components which goes into
the watercraft is the lower housing support
(LHS). The lower housing support is
designed to support the impeller housing.
The president of the Company, Mr. Seemore
Waste, has asked us to investigate the
production of this component to determine if Final Assembly =
there is any way cost, quality, and delivery of Lower Housing Support (LHS)
this critical component can be improved.

3. CURRENT STATE Work Instruction
Production Manager Only
CONDITION
The Lower Housing Support (LHS) is
manufactured in-house using a four-step
process:
1.Welding
2.Riveting
3.Bolt-on
4.Packing
There are four different LHS Models, all
look similar, but are, in fact, slightly
different. The LHS is built and
transported to next station in
lots of six units and is composed of:
• Three (3) cross-members, which are
purchased from a supplier
• Three (3) upper struts which come
pre-assembled from a supplier
The production control methodology is
based on a “PUSH” system, all parts in
the production system are delivered to
the next operation as soon as they are
complete and without Delay.

4. Work Instruction
Production Manager Only
Target Objective
The target objective of this exercise is to improve the current state condition
Target conditions for improvement could be > 5 Principles of Lean Thinking and 7 Wastes.
The exercise will be allowed to run through three independent cycles to install PDCA thinking
The first cycle will be used to establish BASELINE measurements of the current state condition
The next two cycles will be to develop and then test and trial alternatives of improvement
The following metrics will be used to evaluate the Baseline and measure your performance.
• Cycle-time • Quality
• Work-in-process • Output per unit of time
• Distance • Number of people
• Space • Waste Visibility
A form to measure results is included in this instruction set, please see Form 2 next page, followed by a
production workflow diagram to be used as a flight simulator layout reference guide.
Each participant will receive instructions from you the Production Manager regarding their roles and
responsibilities at their assignments at each of the production system workstations.

5. Measurement
Production Manager
EXERCISE EVALUATION/MEASUREMENT FORM 2 Production Controller
Current Alternative 1 Alternative 2 Improvement
Metrics
Condition Test Trial Test Trial Alt 2 compared to
Elements to be measured Results Baseline
Baseline Results
Work-in-process (# of Units)
Part Travel
Distance/Proximity (Steps)
Cycle Time (Min)
Quality Rate
(# of Defective Assemblies)
Space (Sq Ft)
# of people (Head Count)
Output per unit of time (RED LOT)
(Total Units produced / Total Time)
Waste visibility (Subjective)
Print on E-size Banner for Final Tally + Print 2x 8.5 x 11 for use by Production Manager and Production Controller

6. Work Instruction
Production Manager Only
WORK FLOW for CURRENT STATE CONDITION

7. Work Instruction
Production Controller
PRODUCTION CONTROLLER
Your role is to explain the expected
production schedule and output and how
work flows to all operators and you will also
expedite parts to starved workstations as
required.
It is up to you and the Production Manager
to keep the production line running.
Unless you are told otherwise, the final
assembly production schedule is as follows:
White 3 lots
Red 1 lot
Green 2 lots
Black 2 lots

8. Work Instruction
FINAL ASSEMBLY Final Assembly
OPERATOR (CUSTOMER)
You operate the final assembly station
where the Lower Housing Support
(LHS) is installed on a variety of
products. The final assembly line is
located at the other end of the plant
and you are quite a distance away
from the LHS production area. To
simulate the final assembly activity,
you are to verify that the LHS has
been built correctly by comparing it to
the drawing to the right: Defect
If you identify a non-conforming
assembly, set it aside and notify the
LHS area Production Manager
immediately; if you can’t find him/her
or don’t have time to locate him/her,
tell the Material Handler.
After you have checked each
component thoroughly, further
simulate the final assembly process by
breaking the product down into the
component parts.

9. Work Instruction
Warehouse Attendant
WAREHOUSE ATTENDANT
All components purchased on the outside
are received and inspected to an “AQL”
specification before they are brought to
you for storage. Your job is to keep all
the work stations supplied with the parts
and keep production running smoothly.
Since the product is made in lots, you are
to kit and stage 12 cross-members (all
the same color) at a time for WELDING
and 4 upper-strut assemblies (all the
same color) at a time for the BOLT-ON
operation.
However, every third lot, will be held up
for 10 seconds for inspection by the
Production Controller. Call out to the
Production Controller when you need
parts inspected.
All parts will be moved from the
warehouse to production area by a The raw materials look like this.
Material Handler; call for the Material
Handler whenever you have parts ready
for transport.

10. Work Instruction
Production Manager Only
Production Manager
Your job is to make sure everyone is
productive, the OPERATORS are
following work instruction and
performing their operations correctly,
and that the production line is never
idled.
Since you are the only person in
authority here, you will have to
provide all instruction to the station
operators. At certain points in the
exercise, you may need to follow the
direction of the instructor. So listen for
direction
There is a PRODUCTION
CONTROLLER who will provide a
production schedule and help
expedite for you.
NOTE: Defective / Non-Conforming
products ARE NOT repairable.

11. Work Instruction
Production Manager Production Manager Only
The finished product looks like this
Your customer is the FINAL ASSEMBLY line which is at the other end of the
plant. If the final assembly line is shut down, it costs the company $100,000
per hour.
Note: It is also part of your job to assist the instructor in the collection of data
on each of the measurements denoted on the scorecard which will be used
to measure each cycle of this exercise.

12. BOLT ON
Work Instruction
BOLT-ON Operator
Your task is to bolt the upper-strut
assembly to the cross-member
assembly. The colors must match.
Your work should look like this:
Your finished product goes to the
PACKER STATION.
Call the Material Handler when you
need him/her and he/she will
transport your WIP for you.

13. RIVET
Work Instruction
RIVET Operator
Your job is to rivet the remaining
cross-member (of the same color)
onto the two which have been
welded. The output of your work
station should look like this:
Finished parts go to the BOLT ON
workstation next.
A material handler will transport
WIP there for you, call for the
Material Handler if you need
him/her.

14. PACKER
Work Instruction
PACKER Operator
Your job is to pack the parts
individually in plastic bags and seal
them shut.
Call our for the Material Handler if
you need him/her. The Material
Handler will transport materials to
the FINAL ASSEMBLY area for you.
You are also responsible for
INSPECTING the finished LHS
units.
If you find any Non-Conforming
parts, immediately. notify the
Production Manager
A completed unit should look like
this:

15. WELDER
Work Instruction
WELDER Operator
Your job is to weld two of the
cross-members together; they
must be of the same color.
The parts should be welded to
form the shape to the right.
Your work goes to the RIVET
operation next. The Material
Handler will transport your WIP
for you.
Call out for the Material Handler
if you need his/her assistance.

16. MATERIAL HANDLER
Work Instruction
MATERIAL HANDLER
Your job is to move parts from one
workstation to the next, including
delivery of raw materials from the
warehouse to the work stations and
the delivery of finished product to the
final assembly line.
All transportation of material is your
responsibility. No-one else can
move/transport materials except you.
RULE: Each lot is 6 six units. You
can only move complete lots. You
can carry, at most, 3 three lots at a
time and they must be in a plastic
bin provided to you from the
warehouse.

17. Workstation
Identification
Standard
Placards
Action
Print in Color and Place at Work Stations

18. Placard
WAREHOUSE
Quality Sampling Standard:
Remember every third lot, will be held up 10 seconds for inspection
Place on workstation table

19. Placard
BOLT - ON
Place on workstation table

20. Placard
RIVET
Place on workstation table

21. Placard
WELDER
Place on workstation table

22. Placard
PACKER
Place on workstation table

23. Placard
FINAL ASSEMBLY
Customer
Place on workstation table

24. STANDARD
FORMS

25. FORM
FORM 1
FINAL ASSEMBLY PRODUCTION SCHEDULE
White 3 lots
Red 1 lot
Green 2 lots
Black 2 lots
1 LOT = 6 Final Assemblies
If you desire, please print and post for students to See

26. FORM
FORM 2
EXERCISE EVALUATION/MEASUREMENT SCORECARD
Current Alternative 1 Alternative 2 Improvement
Elements to be measured
Condition Test Trial Test Trial Alt 2 compared to
(UOM) Results Baseline
Baseline Results
Work-in-process (# of Units)
Part Travel
Distance/Proximity (Steps)
Cycle Time (Min)
Quality Rate
(# of Defective Assemblies)
Space (Sq Ft)
# of people (Head Count) 9
Output per unit of time
(RED LOT Sample)
(Total Units produced / Total Time)
Hard to See Harder to See Harder to See
Waste visibility (Subjective)
Easy to See Easier to See Easier to See
Print on E-size Banner for Final Tally + Print on 8.5 x 11 for use by Production Manager and Production Controller

27. Form 3 FORM
FINAL ASSEMBLY QUALITY
Non-Conforming Material Measurement UOM = Count
Final Assembly Quality
# of Non-Conforming # of Non-Conforming # of Non-Conforming
Assemblies Assemblies Assemblies
Color Current Condition 1st Alternative 2nd Alternative
Test and Trial Test and Trial
WHITE
18 pcs
RED
6 pcs
GREEN
12 pcs
BLACK
12 pcs
Print 8.5 x 11 for use by Final Assembly Operator, place at work station

28. Instructors Guide
Waste Identification and Elimination Exercise
Purpose: Educate and establish new knowledge and new capability in the
students to “See Waste” and Measure Waste by challenging the students to
work together to identify, reduce and eliminate 7 Wastes present in the
exercise. Most importantly build “KAIZEN Spirit” and “Challenge Spirit”!
If the Student has not learned, the Teacher has not taught!

29. Waste Identification and Elimination Exercise Bill of Materials
Lego “Duplos” (LARGE LEGO’s if you can locate a source are advised > SMALL LEGO’s will work as well)
50 pcs > RED (2x4 connector)
50 pcs > RED (2x2 connector)
50 pcs BLACK (2x2 connector)
50 pcs BLACK (2x4 connector)
50 pcs GREEN (2x2 connector)
50 pcs GREEN (2x4 connector)
50 pcs WHITE (2x2 connector)
50 pcs WHTE (2x4 connector)
Prior to Start of Exercise Pre-Assemble “Upper Struts” >
Pre-Stage Upper Strut Sub-Assemblies @ Warehouse
Upper Strut Subassembly Material Requirements are:
18 pcs > WHITE Upper Strut Sub-Assembly
6 pcs > RED
12 pcs > GREEN
12 pcs BLACK

30. Waste Identification and Elimination Exercise Bill of Materials
1 Instruction Deck for Production Manager (Slides 1-15 of this deck)
15 plastic containers (Pre-Stage in Warehouse)
Measurement
Production Manager
1 Box of Medium Sized Zip-Lock Baggies
EXERCISE EVALUATION/MEASUREMENT FORM 2 Production Controller
Current Alternative 2 Improvement
Metrics Alternative 1
Condition Alt 2
Test Trial Test Trial
Elements to be measured compared to
Baseline Results Results Baseline
Work-in-process (# of Units)
Distance/Proximity (Steps)
1 E-Size Exercise Measurement (Form 1)
Pre-Stage by hanging on Wall. Alt > Hand Write scorecard on White Board
Cycle Time (Min)
Quality Rate
(# of Defective Assemblies)
Space (Sq Ft)
# of people (Head Count)
Output per unit of time (RED LOT)
1 calculator (if required)
(Total Units produced / Total Time)
Waste visibility (Subjective)
3 stop watches
1>One for Assistant 1 to measure Total Time of Exercise
1>One for Production Controller to Measure RED LOT cycle time
1>One for Assistant 2 to measure RED LOT production as
backup to Production Controller’s measurement activity
Form 3 FORM
FINAL ASSEMBLY QUALITY
Non-Conforming Material Measurement UOM = Count
Final Assembly Quality
# of Non-Conforming # of Non-Conforming # of Non-Conforming
Assemblies Assemblies Assemblies
Color Current Condition 1st Alternative 2nd Alternative
Test and Trial Test and Trial
WHITE
18 pcs
RED
6 pcs
1 Flip chart (use during team improvement dialogue
GREEN
12 pcs
BLACK
12 pcs
3 Markers for use during alternative development
1 Quality Rate Scorecard for Final Assembly
6 Tables: 1 for each workstation and Warehouse
6 ID Placards one for each work station and Warehouse

31. Waste Identification and Elimination Exercise
Number of Participants:
1 Instructor
2 Assistants in training to become instructors
9 Students / Participants
1. Production Manager
2. Production Controller
3. Material Handler
4. Warehouse Attendant
5. Welding Operator
6. Rivet Operator
7, Bolt On Operator
8. Final Assembly Operator
9. Packer Operator

32. Waste Identification and Elimination Exercise
Exercise Layout: Room selection is key.
Pick as large a room as possible.
Alternative: Conduct exercise offsite at a hotel at a conference center. The bigger the better.
Your intentions are to have people travel un-necessarily and to deliberately cause and create 3M
Muda, Mura, and Muri from the ensuing chaos and confusion!
Locate the Warehouse as far away from the workstations as geographically possible.
If possible, locate warehouse outside of the room where the exercise is being conducted.
Review the assembly sequence of operations (see diagram) and intentionally locate workstations to
generate the greatest distance between them as possible based on the room size, create the worst
case spaghetti diagram you can!
Place PLACARDS for each workstation and Warehouse on corresponding table
Locate baggies, Lego’s, bins , pre-assembled upper struts
and Bins on the Warehouse Table. No materials should be located at workstations.
Locate Non-Conforming Material Scorecard at Final
Assembly table
Placard
Hang Exercise Evaluation/Measurement Tally sheet on wall in room. E-size Print. WAREHOUSE
Quality Sampling Standard:
Remember every third lot, will be held up 10 seconds for inspection
You can also print out the Production schedule in E-Size print and hang on wall if you so desire.
Place on workstation table
Form 3 FORM Measurement
Production Manager
FINAL ASSEMBLY QUALITY EXERCISE EVALUATION/MEASUREMENT FORM 2 Production Controller
Non-Conforming Material Measurement UOM = Count
Current Alternative 2 Improvement
Metrics Alternative 1
Condition Alt 2
Test Trial
Final Assembly Quality Elements to be measured
Baseline Results
Test Trial
Results
compared to
Baseline
# of Non-Conforming # of Non-Conforming # of Non-Conforming
Assemblies Assemblies Assemblies Work-in-process (# of Units)
Color Current Condition 1st Alternative 2nd Alternative
Test and Trial Test and Trial Distance/Proximity (Steps)
WHITE Cycle Time (Min)
18 pcs Quality Rate
RED (# of Defective Assemblies)
6 pcs Space (Sq Ft)
GREEN # of people (Head Count)
12 pcs Output per unit of time (RED LOT)
BLACK (Total Units produced / Total Time)
12 pcs Waste visibility (Subjective)

33. Waste Identification and Elimination Exercise
Instructor and Assistants Preparation Standard Work Instructions
Prior to Exercise:
Who: Instructor and 2 Assistants
 Set up the exercise and rehearse the exercise 2x with your assistants
 Read the Production Managers instruction deck several times and thoroughly understand all of details as shallow as they are!
 You and your assistants should be able to complete all workstation activities and teach them to others
 “You DO NOT want to make up rules during exercise” BE PREPARED
 Become intimately aware of all of the requirements of the exercise
 Choreograph your activities and those of your assistants in the exercise (KATA’s)
 Create hand written notes when you begin to question yourself and reflect > your delivery patter and your movements (KATA’s) and the
corresponding exercise roles and responsibilities should be crystal clear.
 Become proficient in all aspects of the exercise.
 Thoroughness is key, build capability to perform exercise Learn by Doing.
 Remember you are the instructor it is your duty to create new knowledge and capability in your students
 Never let your students FAIL to Learn
 Learn how to use the stop watch and be able to instruct others in the use of the stop watch.
 You and your assistants will need to be able to properly use the stop watch during specific elements of measurement during exercise
 Special Note: One of the assistants will be required to use stop watch to measure time of RED LOT production. The Production Controller is
on point to perform the measurement activity, but may be become overwhelmed and forget to measure RED LOT production during exercise,
therefore backup will be required.
 The assistants measurement of RED LOT production time is performed without the knowledge of the students.
 When you and your assistants have established the confidence to perform exercise through demonstrated proficiency and new competency then
schedule date and formally prepare for delivery of exercise.
 Once you have layout complete and before you start the exercise perform the following measurements.
 Measure work area using UOM=Sq Ft approximations only. Precision is not necessary >fill calc in Form 2 “Space”
 Step off distances between work stations and Total, fill in Form 2 “Part Travel Distance/Proximity UOM=Steps

34. Exercise Kick-Off
Short Interval Training
Learning by Doing is the focus and aim of the exercise
Depending on the level of “Lean Thinking Capability” present in the students I would advocate that short interval training should
take place prior to start of the exercise.
Duration: 30 minutes maximum, shallow instruction, but instruction non-the-less.
Just enough to poke the minds of the students.
Personally I use a E-Size print outs hung on wall for teaching..
NO POWER POINT allowed > High Touch, No Tech Low tech learning environment.
Let your conscious be your guide as to the method you select for teaching
Here are some subjects that I would suggest: (see next 3 slides as examples)
Discuss the 5 Principles of Lean Thinking
Discuss KAIZEN spirit
Discuss Closed Loop Thinking PDCA > SDCA
Discuss the 7 Original Wastes
Discuss 3M Muda Mura and Muri
Discuss Standard Work
Discuss Standard Work Sheets
Discuss 3Gen > Genchi > Genbutsu > Genjitsu
You may choose other topics to teach.
Keep short interval training “out of the weeds”
When you have completed the exercise return to the topic and content you chose to teach and reflect with the students on HOW
the short interval training you instructed ties to the exercise. Use examples from the exercise as the basis of creating the tie.

35. Start Exercise with Short Interval Training (30 minutes)
2 Topics > 5 Principles + Seven Wastes
Discuss each Principle and Each of the Original Seven Wastes
Tie Exercise to Both Topics
5 Principles of Lean: Seven Original Wastes:
VALUE - What the customer is willing
to pay for
Unnecessary
T ransportation
VALUE STREAM - All the required
Unnecessary
I nventory
steps to produce and deliver a product Unnecessary
M otion
or service Unnecessary
W aiting
FLOW - A product moving through the
value stream with no stoppages, scrap
Unnecessary O ver-production
or rework
Unnecessary O ver-processing
PULL - producing and delivering only D efects
when the downstream customer
signals a need
The Eighth Waste is:
PERFECTION - completely eliminating Not using People’s Intellect
waste so that all activities create
value

36. 3M’s – One Point Lesson
Type I: 無駄 MUDA = NON-VALUE ADDED ACTIVITY
Any Activity that is wasteful and doesn't add value or is
unproductive
Type II: 斑 or ムラ MURA = INCONSISTENCY
Condition of unevenness, inconsistency in physical
matter or human spiritual condition – Absence of
Balance - Variability
Type III: 無理 MURI = UNREASONABLENESS
Condition of overburden, unreasonableness or absurdity
Inflexibility

37. Value Stream – One Point Lesson
Created by: Todd McCann
VALUE STREAM - All the required steps to produce and deliver a product or service.
Also known as “Material and Information” flows
Value Stream Mapping is a tool that allows individuals to:
 Visualize end to end FLOW of MATERIAL and INFORMATION to create a product
 Primary Objective > Expose and quantify stagnant inventory that is not FLOWING
Quantify all VALUE added and NON VALUE added activities in the Value Stream
 Identify constraints and process bottlenecks prohibiting FLOW in the Value Stream
 Determine areas in need of improvement to increase FLOW in the Value Stream, create PULL where you can
 Set improvement goals and easily identify the correct process improvement indicators in the Value Stream
 Use as “The Blue Print” to enable continuous improvement behaviors
 Enables the creation of standard work in the Value Stream
• Deliver exactly what the customer wants
• One at a Time
• On Demand
• Free of Defects
• Respond Immediately to Problems
• Increase Value by focusing on
continuous elimination of waste in pursuit
of Perfection!
CURRENT State Condition IDEAL State Condition