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One of the most important learning's I took from the experience was how effective rapid prototyping and hands on experimenting could be in an event. The Sensei went from team to team throughout the event and kept telling us to stop brainstorming and start "trystorming (actual simulation or creation of the idea)." This meant putting away the flip charts and sticky notes and getting out on the floor and getting our hands dirty. Having the 3D, tangible "mock-ups" allowed the teams to quickly understand each others ideas and iteratively improve the solution in a way that would not be possible on paper. Simulations became real and many of the bugs of standard work could be worked out in advance prior to a "down stream" implementation.

Good simulation of benefits of single piece flow.

Use these in our CI Class

How could we use this in POD for example? Obviously, the manufacturer has taken an existing batch process, moved to single piece flow and seen tremendous results. The benefits are clear. Reduced inventory and faster delivery times. This alone will make any manufacturer more competitive. But lean doesn't stop here. Any process can be optimized and, when cost and space allows, moving to a flexible work cell is the logical next step.

Or you can show this 47 second video! In "real time", you can see how quickly the customer receives their order. You can see the reduction in inventory. You can see less work in process. And you can see the order fulfilled in 29 seconds vs 60. Half the time! Imagine how much time you save with a longer chain of processes. Because the video's so short, you can easily work it into your session, between phases of a lean game or after a more intensive sit and listen session.

Who could facilitate a Lego game for us?  I would love to participate.

There is no reason that we can't try.

Oh, and "senior management" . . . would be nice to do the game and video the event for company distribution. A fun learning tool -- which reminds me of what a vendor said yesterday: "People learn best when playing games."

Nice article on how to use the Fish Bone diagram.

After 4 posts about value stream mapping, I thought it would be useful to show a value stream map example. It's easier to learn by seeing examples of how other people use this lean tool.

Might be a good video to watch for those in a non-manufacturing environment.

NEVER!

Correct! We will not recognize Tweddle in a matter of years, because of all of the improvements.