Paper Airplane Exercise: Provided To NWLEAN by Tim Leach of Northrup Grumman, May 98
Paper Airplane Exercise: Provided To NWLEAN by Tim Leach of Northrup Grumman, May 98
Paper Airplane Exercise: Provided To NWLEAN by Tim Leach of Northrup Grumman, May 98
3 Simulations
• 6pc Batch (Push)
• 3pc Batch (Push)
• Single Piece Flow (Pull)
Measure
• Completed Units
• Throughput (Regular and “Hot” Production)
• Work-In-Process
• Observations (Worker Environment)
2
Materials Required
• 200 Sheets of Paper (Approx.)
– To make Paper Airplanes
• 50 Paper Clips
– To Use as “Carts” for Transporting W.I.P. & Planes
• Masking Tape
– To Mark-Off Queue Boxes and Work Areas for
Exercise
• Dry Erase Markers
– For White Board or Flip Chart Tracking of Exercise
Activities
– One or More of: White Board / Chalk Board / Flip
Chart
• “Paper Airplane Mfg., Co.” Tracking Sheet
– To Record Exercise Results and Participants
• Stop Watch or Watch with a Second Hand
3
Simulation Physical Layout
• Eight Participants
- Material Identification - Wing Fold
- Fuselage Fold - Shipping
- Nose Fold #1 - Customer (Boeing)
- Nose Fold #2 - Material Handler
– Clearly identify “Queue” boxes between each station
– Work in designated work area
– No work to be done within “Queue” boxes
– Only Material Handler moves material in 6pc & 3 pc
simulations
• Everyone Else Observes
• 6 Minutes per Simulation -- Stop ALL Activity at 6 Minutes
• Introduce “Hot” Plane at 2 - 3 - 4 Minute Marks
• Record Measurables and Observations After Each 6 Minute
Simulation
4
Simulation Physical Layout
6 3 1
Facilitator
QTY PROD
“HOT”
Observations
Customer Shipping Wing
6: Customer Receiving Shipping “Queue” Fold
3:
1:
5
Pre-Exercise Preparation
• Visual Aids
– The Exercise Will have 5 Stations Requiring Visual
Aids
• See Work Station Examples
• Tape Off “Queue” Boxes With the Masking Tape
– (Re: Simulation Physical Layout)
– Write on the Taped “Queue” Box What “Queue”
Box It Represents
– Make Sure to Spread the Seats Apart for Clear
Separation of “Work” Stations Between the
“Queue” Boxes
• Identify Work Areas With One Strip of Tape and Label
Them
6
Pre-Exercise Preparation
• Line Primed or System Filled
– If the Exercise is Produced With the Line Primed (a
Batch Set in Each “Queue” Box Prior to Starting
Each Simulation), the Facilitator Will Need to Have
These Ready Prior to the Exercise (This Saves
Time During the Exercise)
– Line Empty
– If the Exercise is Produced With the Line Empty
(No Parts in the Line at the Start of Each
Simulation), then No Pre-Folding of Planes is
Required
– The Exercise can be Produced Either Way -
However all Three Simulations in the Exercise Must
be Produced the Same Way (Primed or Empty)
7
Work Station Examples
MATERIAL IDENTIFICATION NOSE FOLD #2
Paper Clip
“Cart”
04/10/98 Lot #1
11
Facilitator Instructions (Continued)
12
Facilitator Instructions (Continued)
13
Facilitator Instructions (Continued)
• 1pc Flow
– The paper clips will no longer be used
– The participants must completely understand that they
can perform work ONLY when their Customer “Queue”
box is empty - Giving them their VISUAL TRIGGER to
produce another product to replenish their Customer’s
DEMAND (the Cradle of Takt Time)
• To make this point clear: If the Customer’s “Queue”
box has a part in it, that operator CANNOT be
working on a new part ....... Period
14
Facilitator Instructions (Continued)
15