BLACK DOT WASTE IDENTIFICATION SKIT – TRAINERS GUIDE

This skit is designed to demonstrate where value is created for a customer and to identify waste as business value (or enabling waste) and pure waste TIMWOOD.

PREPARATION

Trainer prior to the start stores a black flip chart pen a few metres from a flipchart/whiteboard.

Then explain what value added is; value in the eyes of the customer (something that they would pay for), the process step changes the fit, form or function and is done right first time. Explain that waste is everything else but can be categorised into business value (or enabling waste) – waste that is necessary under the current situation e.g. legal or regulatory requirements, technical or physical limitations etc. Then explain pure waste as TIMWOOD. Write TIMWOOD on a flipchart or white board you intend to use for the skit and explain what each element means (if not done earlier in training).

TransportationInventoryMotionWaitingOver productionOver processingDefects

Point out that we should aim to maximise value, minimise business value/enabling waste and eliminate pure waste. Also state that the ‘perfect’ solution only produces value and no waste.

SKIT

Trainer chooses a delegate to act as a customer and asks them to pretend to order a ‘black dot’ via a phone call.

Use a hand to ear mime of a phone (or whatever suits) and have a conversation with the customer about irrelevant things e.g. the weather, their family, news topic etc (waste time). Then ask what they wanted. Seek the response “a black dot”.

Thank them for the order and locate the black pen stored earlier and walk to retrieve and bring back to flipchart/whiteboard. Place three black dots circa 5mm (1/4”) diameter on the chart/board and replace the pen in its chosen remote position.

Call the customer back, waste more time and show them their black spot. (Then outside the phone call tell them to say that it is too small and that they wanted a 1cm (1/2”) black spot). Act surprised and apologetic; perhaps say that they should have said so first time or maybe you should have asked them.

‘Replace the phone’ and repeat making the three black spots 1cm (1/2”) diameter (check against thumb nail or measure as a gauge).

Call the customer back and tell them to say that that is OK (order satisfied) and replace the ‘phone’.

REVIEW

Now ask the delegates where was the value added? Prompt for one definite (placing ink on the paper/board to form a dot of the right specification) and a second possible value adding activity (ask “was the conversation valued by the customer?” Allow debate and then ask the customer!).

Next, ask where the pure waste was. Allow discussion and offer guidance. After a while and to prompt a greater level of thinking ask “what is the ‘perfect’ solution” and demonstrate e.g. pen touching the board at the right place, only one spot produced at the right size, produced instantaneously etc. Seek practical solutions. Possible answers for waste include:

Transportation – carrying the pen to and from the boardInventory – three dots on chart/board plus (leave this until later as it is more subtle)

ink stored in the pen ($1000 per dot!)Motion – walking to get pen, too many circles to draw 1cm, awkward writing angle

on board (possible)Waiting – wasted time chatting, lead time to produce job vs value adding time

(demonstrate Process Cycle Efficiency PCE = VA time / total time)Overproduction – producing three dots instead of oneOver processing – pen nib size not 1cm, flipchart size too large, skilled trainer to make black

dotsDefects – incorrect dot size first time, misshapen(?)

Next, ask where is the business value/enabling waste. Possible answers include:

1. Getting the specification (ask what is the best way to do this – email, web?)

2. Something or someone has to draw the black spot.

3. The spot has to be sent to the customer.

4. The cap on the pen has to be replaced (to avoid the ink drying out – technical limitation)

The trainer can build on this as they see fit to illustrate waste and value added and how to ‘see’ waste. Done well, this really gets, even moderately experienced people, to see waste better.

End.