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WarehouseSimulationGame
DuringtheWarehouseSimulationGametheprinciplesofLeanareshownandweaskyoutoapplythemonthespot
Thegamemakesyouthinkaboutwhatisvalueaddforthecustomer,whatistheemployee’sroleandvalueaddintheprocess,andtoletgooftraditionalrolesandseeminglyindependenttasks
ThegoalistomakeLeanmoreconcreteandeasiertoapply
ItisaninteractivewaytogetyouacquaintedwiththeLeanprinciples.
2
Tounderstandtheopportunitytoimprovequality,cost,anddeliveryperformanceintraditionalwarehousing
TogainanawarenessofhowJITwarehousingdiffersfromtraditionalwarehousing
Togainanappreciationofthefollowing'LEAN'terms:
Eighttypesofwaste
Continuousflowprocessing
Takttime
Objectives
3
Agenda
Caseintroduction
Practiceround
Round1“Waste”
Round2“Flow”
Round3“Takt”
Summary
4
Run
(do)
Redesign&
Prepare
(plan)
Analyze
(check)
LEAN
theory&examples
(act)
Structureofsimulationrounds
“Setupnewround”
“Designimprovedwarehousesystem”
“Simulateoperation”
“Measureperformanceandidentifyissues”
5
Agenda
Caseintroduction
Practiceround
Round1“Waste”
Round2“Flow”
Round3“Takt”
Summary
6
Context
Youare6,12,18,or24employeesinawarehousethatproduceskitsfortheconsumerindustry
Thepackingfortheseproductsrequiresspecialtreatment,buthasasimilarsetup
Thecompanyiscurrentlyunabletodeliverthequality,cost,anddeliverypromisesmadetoitscustomers
7
Operation
Eachorderismadefrom¼sheetofA4,1photofilmtubeand2to12paperclips
Eachoperatorhasaworkstationwith1workinstruction
1
Receiveandcheckpacking
2
Cutpackingintoquartersheets
3
Preparebox,addpicklist
4
Pickpackitemsrequiredfororder
QC
Ship
&
5
Checkquality,sealorder
6
Materialhandler
8
Units
Goal
Numberofgoodordersdelivered
Percentwrongpicked/packeditemsfromtotalnumberofitems
Goodordersdelivered/numberofemployees
Numberof1/4papersheetsinproductionarea
Averagethroughputtime(minutes)
Indexedagainstround1(=100%)
Trackingkeyperformanceindicators
9
Agenda
Caseintroduction
Practiceround
Round1“Waste”
Round2“Flow”
Round3“Takt”
Summary
10