精益生产之仓库模拟游戏

Warehouse Simulation Game

精益生产之仓库模拟游戏

Warehouse Simulation Game

During the Warehouse Simulation Game the principles of Lean are shown and we ask you to apply them on the spot The game makes you think about what is value add for the customer, what is the employee’s role and value add in the process, and to let go of traditional roles and seemingly independent tasks The goal is to make Lean more concrete and easier to apply It is an interactive way to get you acquainted with the Lean principles.

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11 September 2013

精益生产之仓库模拟游戏

Objectives

To understand the opportunity to improve quality, cost, and delivery performance in traditional warehousing To gain an awareness of how JIT warehousing differs from traditional warehousing To gain an appreciation of the following 'LEAN' terms: - Eight types of waste - Continuous flow processing - Takt time

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11 September 2013

精益生产之仓库模拟游戏

Agenda Case introduction

Practice round Round 1 “Waste”

Round 2 “Flow” Round 3 “Takt” Summary

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11 September 2013

精益生产之仓库模拟游戏

Structure of simulation rounds

“Design improved warehouse system”

LEAN theory & examples (act)

“Set up new round”Redesign & Prepare (plan)

Analyze (check) Run (do)

“Measure performance and identify issues”

“Simulate operation”

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11 September 2013

精益生产之仓库模拟游戏

Agenda Case introduction

Practice round Round 1 “Waste”

Round 2 “Flow” Round 3 “Takt” Summary

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11 September 2013

精益生产之仓库模拟游戏

Context

You are 6, 12, 18, or 24 employees in a warehouse that produces kits for the consumer industry

The packing for these products requires special treatment, but has a similar setup

The company is currently unable to deliver the quality, cost, and delivery promises made to its customers

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11 September 2013

精益生产之仓库模拟游戏

Operation1 2 3 4 5 6

QC & ShipReceive and check packing Cut packing into quarter sheets Prepare box, add pick list Pick pack items required for order Check quality, seal order Material handler

Each order is made from ¼ sheet of A4, 1 photo film tube and 2 to 12 paperclips Each operator has a workstation with 1 work instruction

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11 September 2013

精益生产之仓库模拟游戏

Tracking key performance indicatorsKPI1.2. 3. 4. 5. 6. 7.

Description

Cost or Revenue Revenue Cost Cost

€ €100 - €50 - €50 - €10 - €100 - €200

Comment

QuantityLate penalty Quality penalty WIP Space Personnel Overhead

# of correct orders delivered# of orders lateUnits

Goal

# of incorrect orders delivered

Number of good orders delivered Percent wrong picked/packed items

Number of 1/4 paper sheets in from total number of items Cost production area

Good orders delivered/number of # tables used employees Cost

# employees Number of 1/4 paper sheets in Costproduction area

Cost

- €300

Fixed

8. 9.

Productivity Lead Time

Average # orders delivered / #throughput time (minutes) employees Indexed against round 1 (=100%)

Time it takes to finish first order

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11 September 2013

精益生产之仓库模拟游戏

Agenda

Case introduction

Practice round Round 1 “Waste”

Round 2 “Flow” Round 3 “Takt” Summary

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11 September 2013

精益生产之仓库模拟游戏

Agenda Case introduction

Practice round Round 1 “Waste”

Round 2 “Flow” Round 3 “Takt” Summary

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11 September 2013

精益生产之仓库模拟游戏

Round 1: Traditional manufacturing

1. Receipt

4. Pick packing

2. Cutting

6. Material handlerLayout is by process

2m 5. Inspect/ship 3. Preparation

Every process has a batch size of 4 Every batch must be prepared together and the material handler must be requested to deliver the

complete batch to the next process (material handler can only take one batch at a time) Every operator should work as fast as possible

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11 September 2013

精益生产之仓库模拟游戏

Simulation round 1

Customers demand: 24 orders in 10 minutes

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11 September 2013

精益生产之仓库模拟游戏

Time

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11 September 2013

精益生产之仓库模拟游戏

Round 1 analysis: Tracking key performance indicatorsKPI1.2. 3. 4. 5. 6. 7.

Description

Cost or Revenue Revenue Cost Cost

€ €100 - €50 - €50 - €10 - €100 - €200

Comment

QuantityLate penalty Quality penalty WIP Space Personnel Overhead

# of correct orders delivered# of orders lateUnits

Goal

# of incorrect orders delivered

Number of good orders delivered Percent wrong picked/packed items

Number of 1/4 paper sheets in from total number of items Cost production area

Good orders delivered/number of # tables used employees Cost

# employees Number of 1/4 paper sheets in Costproduction area

Cost

- €300

Fixed

8. 9.

Productivity Lead Time

Average # orders delivered / #throughput time (minutes) employees Indexed against round 1 (=100%)

Time it takes to finish first order

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11 September 2013

精益生产之仓库模拟游戏

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