Lean Game Summary Siddhartha Reddy Poluri-2015A7PS0050H

M.Vijay Vikas -2015A4PS0324H

Sai Harshini Irigineni -2016ABPS0698H
Himakar S.A.N. -2015A2TS0496H

Introduction:
This game is played to simulate a production line in which a person operates three machines
one by one and assemble the intermediate product at the end. Three teams of 4 Players(P)
participated in this simulation. Each team has one operator(P4) and three machines (P1, P2,
P3). The game was played in 3 rounds. Each team needs to perform the same task in each
round. There is a time constraint of 7 min/round. Remaining members were assigned as
time keepers.
Game Procedure:

Length of each step

to be cut from each
square =11mm

Observations:
Round-1:
 In round 1 as there is no information of paper color, P4 finds it difficult to reach the
machines in order. A lot of non-value adding time was observed.
 P1, P2, P3 find it difficult to cut the paper accordingly. They used the scale to draw
lines according to the dimensions mentioned. This consumed a lot of time. They used
either scissors or paper cutter to cut the paper.
 Dimensional errors were observed.
 Same with P2 and P3.
 Consumed entire 8 minUnfinished final product.
Round:2
 In round-2 P4s were assisted by sign boards showing which machine to approach
first. There were also signs for processing intermediate products. This was done by
keeping color codes at each position. It became easy for P4 to identify P1, P2 and P3.
This measure has significantly reduced the non-value adding time found in round-1.
 As P4’s time got decreased drastically P1, P2, P3 got more time to work on
intermediate product.
 The difficulties in cutting the paper still existed but the errors were reduced to some
extent. P1, P2, P3 learnt from the previous errors and tried to rectify the errors with
whatever resources they have.
 Consumed entire 8 minUnfinished final product but in a better shape.

(Sign boards)
 (Finished Products)

(Sign Board)

Round-3:
 Sign boards were there similarly as in Round-2
 In order to avoid dimensional errors and excess time consumed for drawing lines
using scale, a device was used. Also the scale and paper setup is no longer required.
 This device not only reduced the time to cut but also the quality of cuts.
 Teams finished their product within 3 minutes and also in very good shape.

Device used to
cut papers.

Finished products with

least errors
Conclusion:

Round-1 Round2
As mentioned in observations implementing Value stream mapping integrated with Visual
management system helped P4s to understand the production steps and also to identify
the machine according to the color code mentioned. This has decreased the non-value
adding time significantly.

Round-2Round-3
Jidoka is nothing but to prevent error so that production never stops. In order to achieve
this, we used Poka-yoke, here a device which helped P1, P2, P3 cut the dimensions
accurately even without using pen and scale. This has again reduced the time significantly
and made the process error proof.