The Lean Training Game Exchange

The Training Game Exchange

© Profero, inc. 2010 1

© Profero, Inc. 2008

Profero, Inc. | Leaders in Lean Enterprise

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

The Training Game

Exchange

Session D3

Monday, March 8, 2010

3:30 pm – 4: 30 pm


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




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!

CreditsThis exercise is based on an exercise from www.superteams.com which was adapted from one created by Kirt Tassmer of Stanley Fastening Systems.The original game was developed by RWD Technologies, Ltd.DDisclaimer

This is for entertainment purposes only. 5S Supply is not liable for any unintended outcomes.


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




1

23

4

5555

6

7 8

9

10

1112

1314

15

16

17

18

19

20

21 22

23

24 25

26

27

28

29

30

31

32

33

34

35

36

37

38

3940

41

42

43

44

45

46

47

48

4950

515151

52

52

53535454

55

5656 5757

5858

5959

60

61

62

63

64

65

6666

6767

6868

3939

70

71

72

73

74

75757575

7676 7777 7878 7979

80

81

82

83

84

858585858686

8787

88

88

89

90

91

92

93

94

95959595

9696

97979898 9999

100

GO!




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?




1

23

4

5555

6

7 8

9

10

1112

1314

15

16

17

18

19

20

21 22

23

24 25

26

27

28

29

30

31

32

33

34

35

36

37

38

3940

41

42

43

44

45

46

47

48

4950

515151

52

52

53535454

55

5656 5757

5858

5959

60

61

62

63

64

65

6666

6767

6868

3939

70

71

72

73

74

75757575

7676 7777 7878 7979

80

81

82

83

84

858585858686

8787

88

88

89

90

91

92

93

94

95959595

9696

97979898 9999

100

Is this an 8, 88, 4, 84???

Were there any quality issues?

Is this 66 or

99? 89 or 68?

Why is 39

listed

twice?Which one is

the 6 and which

one is the 9?




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.




1

23

4

5555

6

7 8

9

10

1112

1314

15

16

17

18

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20

21 22

23

24 25

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31

32

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38

3940

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45

46

47

48

4950

515151

52

52

53535454

55

5656 5757

5858

5959

60

61

62

63

64

65

6666

6767

6868

3939

70

71

72

73

74

75757575

7676 7777 7878 7979

80

81

82

83

84

858585858686

8787

88

88

89

90

91

92

93

94

95959595

9696

97979898 9999

100

Let’s red tag the numbers

we don’t need (51-100)

and the duplicate 39.






1

23

4

5555

6

7 8

9

10

1112

1314

15

16

17

18

19

20

21 22

23

24 25

26

27

28

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31

32

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36

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38

39

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45

46

47

48

4950

515151

52

52

5353545455

5656 5757

5858

5959

60

61

62

63

64

65

6666

6767

6868

3939

70

71

72

73

74

75757575

7676 7777 7878 7979

80

81

82

83

84

858585858686

8787

88

88

89

90

91

92

93

94

95959595

9696

97979898 9999

100




1

23

4

5555

6

7 8

9

10

1112

1314

15

16

17

18

19

20

21 22

23

24 25

26

27

28

29

30

31

32

33

34

35

36

37

38

3940

41

42

43

44

45

46

47

48

4950

515151

52

52

53535454

55

5656 5757

5858

5959

60

61

62

63

64

65

6666

6767

6868

3939

70

71

72

73

74

75757575

7676 7777 7878 7979

80

81

82

83

84

858585858686

8787

88

88

89

90

91

92

93

94

95959595

9696

97979898 9999

100

Now let’s move them to the

5S Red Tag Holding Area.






78781

23

4

5555

6

7 8

9

10

1112

1314

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

4950

515151

52

52

5353545455

5656 5757

5858

5959

60

61

62

63

64

65

6666

6767

6868

3939

70

71

72

73

74

75757575

7676 7777 7979

80

81

82

83

84

858585858686

8787

88

88

89

90

91

92

93

94

95959595

9696

97979898 9999

100




1

23

4

5555

6

7 8

9

10

1112

1314

15

16

17

18

19

20

21 22

23

24 25

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31

32

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46

47

48

4950

3939





• 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

sequential order (1, 2, 3, 4, 5…)

• You will have 30 seconds to complete this

task




1

23

4

5555

6

7 8

9

10

1112

1314

15

16

17

18

19

20

21 22

23

24 25

26

27

28

29

30

31

32

33

34

35

36

37

38

40

41

42

43

44

45

46

47

48

4950

3939

GO!







• 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)






1

23

4

5555

6

7 8

9

10

1112

1314

15

16

17

18

19

20

21 22

23

24 25

26

27

28

29

30

31

32

33

34

35

36

37

38

40

41

42

43

44

45

46

47

48

4950

3939

Let’s rearrange the numbers in

order that we will use them.




1

23

4

5555

6

7 8

9

10

1112

1314

15

16

17

18

19

20

21 22

23

24 25

26

27

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29

30

31

32

33

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47

48

4950

3939






1

23 4 5555 6 7 8 9 10

11 1213 14 15

16

17 1819

20

21 22

23

24 25

26 27 28

29

30

31 32 33 34 35 36 37 38

40

4142

4344 45

46

4748

49

50

3939




1

23 4 5555 6 7 8 9 10

11 1213 14 15

16

17 1819

21 22

23

24 25

26 27 28

29

30

31 32 33 34 35 36 37 38

40

4142

4344 45

46

4748

49

50

3939

Did you notice that we had to work

around a few things like the

numbers that were already there?20





• 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




1

23 4 5555 6 7 8 9 10

11 1213 14 15

16

17 1819

21 22

23

24 25

26 27 28

29

30

31 32 33 34 35 36 37 38

40

4142

4344 45

46

4748

49

50

3939

20

GO!








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

23 4 5555 6 7 8 9 10

11 1213 14 15

16

17 1819

21 22

23

24 25

26 27 28

29

30

31 32 33 34 35 36 37 38

40

4142

4344 45

46

4748

49

50

3939

20

For Shine we will make sure the

numbers are in good working

order. So let’s clean this mess up!




12 3 4 5555 6 7 8 9 10

11 12 13 14 15 16 17 18 19

21 22 23 24 25 26 27 28 29 30

31 32 33 34 35 36 37 38 40

41 42 43 44 45 46 47 48 49 50

3939

20




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




12 3 4 5555 6 7 8 9 10

11 12 13 14 15 16 17 18 19

21 22 23 24 25 26 27 28 29 30

31 32 33 34 35 36 37 38 40

41 42 43 44 45 46 47 48 49 50

3939

20

After looking at all the styles of

font and sizes the team determined

that some of these items can be

standardized.






1 2 3 4 5 6 7 8 9 10

11 12 13 14 15151515 16 17 18 19

21 22 23 24 25252525 26 27 28 29 30

31 32 33 34 35 36 37 38 40

41 42 43 44 45 46 47 48 49 50

3939

20




1 2 3 4 5 6 7 8 9 10

11 12 13 14 15151515 16 17 18 19

21 22 23 24 25252525 26 27 28 29 30

31 32 33 34 35 36 37 38 40

41 42 43 44 45 46 47 48 49 50

3939

20Let’s add some more visuals like

color-coding and lines.






1 2 3 4 5 6 7 8 9 10

11 12 13 14 15151515 16 17 18 19

21 22 23 24 25252525 26 27 28 29 30

31 32 33 34 35 36 37 38 40

41 42 43 44 45 46 47 48 49 50

3939

20


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

9

10

12 11 13 14 15151515

16

17 18 19

21 22 23

24

25252525 26 27 28 29 30

31 32 33

34

35 36 37 38 40

41 42 43 44 45 46 47 48 49 50

20

GO!





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

9

10

12 11 13 14 15151515

16

17 18 19

21 22 23

24

25252525 26 27 28 29 30

31 32 33

34

35 36 37 38 40

41 42 43 44 45 46 47 48 49 50

20





• Let’s do the same exercise after applying

our 5S principles - with a pen or pencil

strike out the numbers 1 through 50 in

sequential order (1, 2, 3, 4, 5…)


task




1 2 3 4 5 6 7 8 9 10

11 12 13 14 15151515 16 17 18 19

21 22 23 24 25252525 26 27 28 29 30

31 32 33 34 35 36 37 38 40

41 42 43 44 45 46 47 48 49 50

3939

20

GO!








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

• Excess materials

• Excessive search time

• Large area

• Cluttered

• Difficult

After

• The correct materials

• Minimal search time

• Smaller area

• Clean, neat &

organized

• Easy






1

23

4

5555

6

7 8

9

10

1112

1314

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

4950

515151

52

52

5353545455

5656 5757

5858

5959

60

61

62

63

64

65

6666

6767

6868

3939

70

71

72

73

74

75757575

7676 7777 7878 7979

80

81

82

83

84

858585858686

8787

88

88

89

90

91

92

93

94

95959595

9696

97979898 9999

100

Before




1 2 3 4 5 6 7 8 9 10

11 12 13 14 15151515 16 17 18 19

21 22 23 24 25252525 26 27 28 29 30

31 32 33 34 35 36 37 38 40

41 42 43 44 45 46 47 48 49 50

3939

20After




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!


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?

Team 3

Team 2

Team 1

Round 2Round 1


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?


Team 3

Team 2

Team 1

Round 2Round 1




Index Card Game

Batch size reduction really works!




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




How to

• Once everyone understands the game,

start the clock

• Act as a “mean” supervisor or manager

and tell the teams to “Go faster!” and

“Hurry”

• Record the time each team finishes.


Report Out

• Which team finished first and why?


1Team 3

5Team 2

10Team 1

TimeBatch Size






Tennis Ball Exercise

Continuous improvement and flow


Background

• Use this exercise to show how teams can

work on continuous improvement and flow

• Number of participants: 4-8 per team

• Time: 30 minutes




Items

• Two Tennis ball cans per team – one with

three tennis balls the other one empty

• Timer

• Post-it notes

• Performed in four rounds


How to – Round 1

• Prior to the exercise, number post-it notes around the table based on the number of people participating– Make sure that the first one is located by you in the front of the room

– Have all the other post-its out of order

• Tell the team that you are the manager

• Demonstrate to the team the how to exactly perform this process and say ”All three balls have pass through both hands from one canister to the other.”




How to – Round 1

• Tell the to start at #1 and move both cans

to the next number until they are finished

and then deliver the cans to you

• Time the entire process

• Act like a “mean” manager – hover over

them. Tell them to hurry and don’t let them

do it their own way. Correct them if they try

to do it a different way than what you

showed them.



• Ask them what it

was like?

4

3

2

1

TimeRound




How to – Round 2

• Tell the team that it wasn’t fast enough. Your

boss is getting on your back about how slow it is.

• This time have them do it exactly the same

except way but really hurry this time! Really bug

them by telling them to “Hurry, go faster!” and

“Come on, do better!”

• If there is a quality issue (like they drop the

tennis balls or the cans) tell them that you are

not happy because you have to write up a

corrective action report now.


How to – Round 3

• Tell the team that it still wasn’t fast enough and they have to do better

• By this time the team really wants to make changes

• Tell them they need to cut the last time in half

• Let them work on solutions, but it has to be “approved” by you first

• Only let them change the order of the numbers (to sequential around the room)

• You’ll probably hear complaints that you don’t let them make changes they want to make. Just tell them that you have “heard this all before.”




How to – Round 4

• Usually by now the time is lower

• Tell the team that you have a friend that

his company does the same thing as you

and they can do it in 1second!

• Challenge the team to come up with any

solution that can match that

• They will probably say it can’t be done or

can we do it the way we want to


How to – Round 4

• Just remind them that they can’t violate

the policy of ”All three balls have

pass through both hands from one

canister to the other.”

• Teams have come up with some pretty

unique solutions

• You can let the team practice before you

take the “offical” time




Report out - Round 4

• Let them talk about what changed form round 1 to 4– How the manager has to let the team come up with ideas

– How a simple thing like flow improves the time

– How they go over the “That’s impossible”stage

• Round 1 – newly trained

• Round 2 – boss yelling at them to just go faster

• Round 3 – limited changes

• Round 4 – Amazing breakthrough




Wrap-up

Comments, questions and

evaluations




Comments - Questions

• What did you think?

• Ideas for improvements

• Think how you apply this to your

organization

• I’ll stick around to answer any questions

• Hopefully you found this educational and

entertaining!


Wrap-up

• Can we apply this to the real world?

• Share an “Ah-ha” – something you

learned, something that’s new, something

that’s different or something that made an

impression on you

• __________________________________

__________________________________




Anthony Manos

• Tony Manos is a Professional

Business Advisor with expertise in

Lean. Trained and certified by the

Department of Commerce,

National Institute of Standards and

Technology (NIST) in Lean

principles and as a trainer in Lean

courses. He is an international

trainer and speaker on Lean

topics.

• Mr. Manos is a Senior Member of

ASQ, SME and AME and is a

Shingo Prize examiner

Host

Feel free to contact me if you have any

comments or questions

Tony Manos

Catalyst

Profero, Inc.

9270 Corsair Road, Suite #18

Frankfort, IL 60423

USA

Cell: 312.718.0078

Fax: 815.469.5601

Email: [email protected]

Website: www.proferoinc.com


Additional Resources

Group 5S Supply






Thank you

Have fun!

Documents

The Lean Training Game Exchange