The University of Texas at San AntonioUTSA@
3/11/2016 - CIP Meeting Center for Advanced Manufacturing and Lean Systems at UTSA 1
Continuous Improvement Professionals
(CIP) Meeting at UTSA
Hung-da Wan, Ph.D.
Associate Professor and Assistant Chair of
Mechanical Engineering Department
University of Texas at San Antonio (UTSA)
Teach Lean while Having Fun:
The Use of Lean Simulation Games
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Agenda
What is simulation game?
And why do we need them?
What games can I find?
The design aspects of simulation games
Some useful tips
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What is
“Lean Simulation Game”?
And Why?
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Demo: A Game for Continuous Improvement
Let’s look at our “Handout Passing” process.
Define the following items of the “process”:
System:
Objective:
(“value” added by the system)
Problem: (opportunity for improvement)
Performance Metrics:
Identify improvement opportunities
Solutions:
Let’s try again
New Performance:
Let’s use the “Best Practice” from now on
Takes more time than it should
Passing handouts to every student quickly
A Class = Teacher + Students + Classroom
seconds
seconds
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Why use simulation games?
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Define the problem according to
customer requirements.
Measure defect rates and collect all
relevant data.
Analyze process data and determine
the capability of the process.
Improve the process and remove
causes of defects.
Control and mistake-proof the process to sustain the improvement.
Definitions of DMAIC Simulation Gamesvs.
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Benefits of Using Simulation Games
An “Active Learning” Pedagogy
Project-based learning
Experienced-based learning
Promotes “Critical Thinking”
Relates theories to reality Reflect!
Interactive, Competitive and Fun!
Students said they vividly remember the game they
played at the beginning of the semester and repeatedly
referring back to what they learned in the game!
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An Emphasis on “Simulation”
Game playing is fun, but the purpose is to
teach Lean concepts.
“Simulation” is important!
Demonstrate selected Lean concepts in a
simplified setting.
Make sure the participants can relate the
activities to their work/life experience.
Now, let’s take a look at a popular “5S” game.
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Activity: The 5S Numbers Game
The numbers represents application forms
submitted to you for review and approval.
Your job is to strike out the numbers from 1 to 49
in correct sequence (Sheet A).
For example: 1 2 3
We will have a 30 second
shift to get as much done
as possible
Superteams, “The 5S Numbers Game,” (http://www.superteams.com/5s-game.php).
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Lean Tool: 5S
5S – A systematic way of creating a safe, efficient,
and highly visible workspace for employees
https://en.wikipedia.org/wiki/5S_(methodology)
Sort
Set in Order
Shine
Standardize
Sustain
整理 Seiri
整頓 Seiton
清掃 Seisou
清潔 Seiketsu
躾 Shitsuke
=
=
=
=
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What Simulation Games
can I find?
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Types of Lean Simulation Games
There are many types of simulation games.
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Game
EnvironmentGame Setting Example
Face-to-Face
Single Player,
Simple Task5S Number Game
Multi-player,
Role-Playing in a SystemLEGO Airplane Assembly
Computer based
Single Player,
Simple TaskFlash-based 5S Game
Multi-player,
Role-Playing in a SystemWeb-based Office Game
From literature review, we found more than 100 lean
simulation games.
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Example: LEGO Airplane Assembly Line
Time: 90 minutes
Participants: 6 Players per Group
4 Assembly Workstations
1 Quality Inspector
1 Teardown Station
Scenarios: 4 Phases
Phase I: Traditional Factory
Phase II: Cellular Layout
Phase III: One Piece Flow with Pull System
Phase IV: Balanced Workload
Product: Airplane made of LEGO
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Example: PC-based “Visual Aid” Games
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Which Game Should I Use?
Beware! Not all games would work for you.
LEGO Airplane Game needs 1.5 to 2 hours
Web-based Game needs internet connection
CAMLS’s Lean Office Game requires 8 people in a team
Choose the games based on your needs and
constraints: Which lean concepts do you want to demonstrate?
How much time do you have?
How many people will participate?
How many instructors would be needed?
How much preparation efforts & cost? Simple is good!
How confident are you to run this game? Easy is good!
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The “Design Aspects”
of
Lean Simulation Games
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What makes a good simulation games?
These three aspects should be considered.
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Objectives &
Constraints
Dynamics of
System
Learning &
Teaching
Experience
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Aspect #1: Objectives & Constraints
Define These in Objectives:
Define the lean concepts/tools to be demonstrated
Performance metrics relevant to the selected lean
concepts/tools
Targeted group of learners
Type of game to be developed/selected
Identify These Constraints:
Consider allotted time, space, budget, number of
participants, number of facilitators, classroom size,
equipment, and any other issues of feasibility.
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Aspect #2: Dynamics of the System
The game must demonstrate the impact of selected
lean tools on relevant performance metrics within
feasibility constraints.
Desired Dynamics of the system:
“Before” Lean: Confusion, frustration, visible
wastes, opportunities of improvement.
“After” Lean: Streamlined, easy to carry out, visible
improvement in metrics.
Other Properties: Fun to play, encourages critical
thinking, sense of competition & achievement, etc.
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Example of Desired “Dynamics” of System
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#1 #2 #3 #44 sec 8 sec 8 sec 16 sec
#1 #2 #3 #4
#1 #2 #3 #410 sec 11 sec 11 sec 12 sec
#1 #2 #3 #4
#1 #2 #3 #416 sec 8 sec 8 sec 4 sec
#1 #2 #3 #4
(a) Cycle Time Difference Not Significant Enough
(b) Bottleneck Position Located Incorrectly
A Simulated System Capable of
Demonstrating Pull Concept
Before “Pull”:
WIP increases by 3 in every 16 seconds
(∆WIP = (1/4 – 1/16)(60) = 11.25 jobs/min).
So, WIP reaches 22.5 jobs within 2 minutes.
After “Pull”:
WIP controlled at 4 jobs (no buffers) or 7 jobs
(buffers between stations) while maintaining
the same throughput.
Incorrect Designs
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Aspect #3: Learning & Teaching Experience
Learning Experience
Interesting and enjoyable.
All participants should have a role.
Allow participants to relate to real-
world application and their daily
job duties.
Slight frustration in “before” phase
makes “after” phase appreciated
and memorable.
The length: long enough to learn
the concept but short enough to
concentrate and feel engaged.
The anxiety of competition and
achievement helps with the
learning experience.
Teaching Experience
Simple logistics in preparation,
execution, and wrapping up, with
reasonable amount of effort.
Results should be predictable and
manageable.
No need to rely on instructor’s
memory, experience, or additional
help from teaching assistants.
When uncertainty is a factor (e.g.,
number of participants, available
facility, etc.), games with higher
flexibility and adaptability is
preferred.
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The “5S Game” is successful, because…
Lean Concept: 5S.
Relevant Metrics: Time to complete each task.
Requirements & Constraints: Single player, simple tasks,
flexible execution time. The game is free.
Desired System Dynamics: With implementation of 5 S’s,
jobs can be completed quicker in each phase.
Game Setting & Logistics: The scattered numbers can be
easily related to office desks or inventory rooms. Preparation
of the numbers sheets are very easy.
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The LEGO game is successful, because…
Lean Concept: Cellular layout,
one piece flow, pull system and Kanban,
and workload balancing.
Relevant Metrics: Throughput, total cycle time,
defect rate, and WIP level.
Requirements & Constraints: 1.5 to 2 hours of game time; 5 to 6
players per team; enough LEGO pieces.
Desired System Dynamics: First phase creates frustration and low
performance in all relevant metrics. With lean tools implemented in
each phase, relevant metrics improves significantly. Results are
predictable.
Game Setting & Logistics: Assembly of LEGO airplane is simple
and fun, and it can be relate to various systems of work flows.
Once LEGO pieces are acquired, the game is easily reproduced.
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Some Useful Tips for you
Simulation games can be very effective teaching tools, when
used correctly.
Know what you need and what it takes.
You can turn simple things into a game: Drawing, paper folding,
dice rolling, math, spelling, ball catching, sticky notes, etc.
Use “Lean Concept” while using the games.
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Continuous Improvement Professionals
(CIP) Meeting at UTSA
Hung-da Wan, Ph.D.
Associate Professor and Assistant Chair of
Mechanical Engineering Department
University of Texas at San Antonio (UTSA)
Teach Lean while Having Fun:
The Use of Lean Simulation Games