L-1Light Fixture Assembly Simulation Worksheet

AGC’s LEAN CONSTRUCTION EDUCATION PROGRAM

LIGHT FIXTURE ASSEMBLY SIMULATION WORKSHEET: TRACKING SHEET Fill out using the steps described below

Eight-Piece Batch Simulation

Four-Piece Batch Simulation

One-Piece Batch Simulation

Number of Completed Fixtures

Number of Fixtures in Progress

Number of Completed Special-Order FixturesCash Flow +$150 for Completed – $50 for WIP

At the end of each round of the simulation you should record the results for your group.

• Note the number of completed batches

• Notethenumberoffixturescompleted

{ Counteachfixturecompletedwithinthebatchesindividually

• Notethenumberoffixturesinprogress

{ Counteachfixtureinprogresswithinthebatchesindividually

• Notethenumberofcompletedspecial-orderfixtures

• Calculatethecashflowfortheproject

{ Foreachcompletedfixture,giveyourgroup$150

{ Foreachfixtureinprogress,subtract$50fromyourtotal

L-2Light Fixture Assembly Simulation Worksheet

AGC’s LEAN CONSTRUCTION EDUCATION PROGRAM

LIGHT FIXTURE ASSEMBLY SIMULATION WORKSHEET: TIMEKEEPER Asthetimekeeper,youstartandstopthesimulations.Eachsimulationlastsexactlyfiveminutes.Youwillalertthefacilitatorattwominutes,atthreeminutes,andagainatfourminutessothefacilitatorcanintroducethespeciallyorderedfixtures.Youmustalsonotethetimewhenthefirstbatchoflightfixturesiscompleted.

Foreachsimulation,followthesesteps:

1. Start the simulation.

2. Attwominutes,alertthefacilitator.

3. Atthreeminutes,alertthefacilitator.

4. Atfourminutes,alertthefacilitator.

5. Notethetimewhenthefirstbatchcompletes.

6. Atfiveminutes,stopthesimulation.

L-3Light Fixture Assembly Simulation Worksheet

AGC’s LEAN CONSTRUCTION EDUCATION PROGRAM

LIGHT FIXTURE ASSEMBLY SIMULATION WORKSHEET: FACILITATOR Asthefacilitator,yourroleistointroduceonespeciallyorderedfixturewhenalertedbythetimekeeperattwo,three,andfourminutes.Todothis,youwillgotothefixtureassemblyapprentice and introduce a colored piece of paper.

Yourroleisnottoaffectproductionqualityorspeed,butsimplytoplacethespeciallyorderedfixturesintheprocess.Takeyourtime.Thespeciallyorderedfixturemusttravelwiththebatchin which it was introduced.

Foreachsimulation,followthesesteps:

1. Whenthetimekeeperindicatestwominutes,provideanewspeciallyorderedfixtureattheassemblyoperationtouseinplaceofastandardfixture.

2. Whenthetimekeeperindicatesthreeminutes,introduceanewspeciallyorderedfixtureat the assembly operation.

3. Whenthetimekeeperindicatesfourminutes,introduceanewspeciallyorderedfixtureat the assembly operation.

L-4Light Fixture Assembly Simulation Worksheet

AGC’s LEAN CONSTRUCTION EDUCATION PROGRAM

LIGHT FIXTURE ASSEMBLY SIMULATION WORKSHEET: APPRENTICE — ASSEMBLY Astheapprentice,yourroleistobeginthelightfixtureassemblyoperation,knowingyourperformancewillbejudgedonhowmanyassembliesyoucomplete.

Foreachsimulation,followthesesteps:

1. 1.Takeasinglesheetofpaperfromthestack.

• Fromtimetotime,thefacilitatorwillprovideaspecialsheetofpapertouseinplace of the standard paper within your batch.

2. Write the batch number on the paper.

• Note:Eachbatchwillcontainthenumberoffixturesequaltothebatchsizeyouareinstructedtouse.So,foraneight-piecebatchsimulation,thereareeightlightfixturesinBatch#1andinBatch#2andsoon.

3. Drawstraightlinesjoiningthediagonalcornersofeachsheetofpaper,asshowninthebelow.

• Repeattheprocessuntilthebatchsizeisreached.

4. Use the paper clip to combine the batch of papers into one package.

5. Passontothejourneyworkerresponsibleforinstalling.

6. Repeatstepsonethroughfive,withanewbatchnumber,untiltimerunsout.

L-5Light Fixture Assembly Simulation Worksheet

AGC’s LEAN CONSTRUCTION EDUCATION PROGRAM

LIGHT FIXTURE ASSEMBLY SIMULATION WORKSHEET: JOURNEYWORKER — INSTALLATION Asthefirstjourneyworker,yourroleistocompletetheinstallationoperationofthelightfixtureproductionprocess,knowingyourperformancewillbejudgedonhowmanyinstalledassemblies you complete.

YourworkwillstartwhenyoureceiveBatch#1.Thepaperswillhavediagonallinesalreadymarked each sheet.

Foreachsimulation,followthesesteps:

1. Removethepaperclip.

2. Takeasinglesheetofpaper.

3. Drawdottedlinesjoiningthemidpointsofoppositesidesofthepaper,asshowninthefigurebelow.(Previouslymarkedlinesappearingray.)

4. Fold the paper in half along its longer side.

5. Repeatuntilallpapersinthebatchhavebeenmarkedappropriatelyandfolded.

6. Onceallthepapersinthebatchhavethelinesandarefolded,combinethemintoabatch,againusingthepaperclip.

7. Passontothejourneyworkerresponsibleforwiringandclipping.

8. Repeatstepsonethroughsevenforeachbatch.

L-6Light Fixture Assembly Simulation Worksheet

AGC’s LEAN CONSTRUCTION EDUCATION PROGRAM

LIGHT FIXTURE ASSEMBLY SIMULATION WORKSHEET: JOURNEYWORKER — WIRE AND CLIP Asthesecondjourneyworker,yourroleistocompletethewire-and-clipoperationofthelightfixtureproductionprocess,knowingyourperformancewillbejudgedonhowmanywire-and-clip assemblies you complete.

YourworkwillstartwhenyoureceiveBatch#1.Thepaperswillbefolded,havediagonallinesjoiningthecornersanddottedlinesjoiningthemidpointsofoppositesides.

Foreachsimulation,followthesesteps:

1. Removethepaperclip.

2. Takeasinglepaperatatime,unfoldingeachonetoexecutetheoperation.

3. Drawstraightlinestojointhemidpointofalladjacentsides,asshowninthefigurebelow.(Previouslymarkedlinesappearingray.)

4. Refold each paper as before.

5. Repeatuntilallpapersinthebatchhavebeenmarkedappropriatelyandfolded.

6. Combine the papers into the batch using the paper clip.

7. Passontothejourneyworkerresponsibleforlampandfinish.

8. Repeatstepsonethroughsevenforeachbatch.

L-7Light Fixture Assembly Simulation Worksheet

AGC’s LEAN CONSTRUCTION EDUCATION PROGRAM

LIGHT FIXTURE ASSEMBLY SIMULATION WORKSHEET: JOURNEYWORKER — LAMP AND FINISH Asthethirdjourneyworker,yourroleistocompletethelampandfinishoperationofthelightfixtureproductionprocess,knowingyourperformancewillbejudgedonhowmanylampandfinishassembliesyoucomplete.

YourworkwillstartwhenyoureceiveBatch#1.Thepaperswillbefolded,havediagonallinesjoiningthecornersandadjacentsidesofthepaper,anddottedlinesjoiningthemidpointsofopposite sides.

Foreachsimulation,followthesesteps:

1. Removethepaperclip.

2. Takeasinglepaperatatime,unfoldingeachtoexecutetheoperation.

3. Drawasolidlineovereachdottedline.

4. Drawstraightlinesparalleltothelongersideofthepapertodividethepaperintofourequalcolumns,asshowninthefigurebelow.(Previouslymarkedlinesappearingray.)

5. Refold the paper.

6. Repeatuntilallpapersinthebatchhavebeenmarkedappropriatelyandfolded.

7. Combine the papers into the lot using the paper clip.

8. Theproductiscomplete.