Lean Paper Airplane Game - PowerPoint Presentation

Slide1

Lean Paper Airplane Game

Grades 6 - 8Slide2

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APICS IS NOT LIABLE FOR THE CONDUCT OF THIRD PARTIES, INCLUDING INSTRUCTORS, AND THE RISK OF INJURY FROM SUCH THIRD PARTIES RESTS ENTIRELY WITH CLIENT AND PROGRAM PARTICIPANTS.PLEASE VISIT WWW.APICS.ORG/SUPPLYCHAINSTEM FOR ALL TERMS OF USE.

 © APICS 2016.  ALL RIGHTS RESERVED.Slide3

Today’s Objectives

Create Awareness of Supply ChainExperience how Supply Chain & STEM work togetherHave fun!Slide4

STEM

ScienceTechnology

EngineeringMathSlide5

Supply Chain

SourceMake

DeliverReuse/RecycleSlide6

Supply Chain and STEM make things happen!

STEM

ScienceTechnology

EngineeringMath

Supply

Chain

Source

Make

Deliver

Reuse/Recycle

+Slide7

Mass ProductionProducing large amounts of standardized products in an assembly line

Example: Ford’s production lineThink “Lean” – do you see any ways (small or big) to improve the process?

Could this process be improved? Is that how cars are made today?Slide8

Work in Process (WIP)Unfinished products in a production process.Slide9

Metrics

Measurement of Performance or Product

Time

Cost

QualitySlide10

Paper Airplane CompetitionSlide11

Team SetupThe class should divide into teams of about 5-7 students/team.

Each team should be seated at their own table – and separated from the other teams.Ensure there is sufficient room to flight test – launching the airplanes towards a wall (away from students, and not towards other teams).

Each team member starts as a design engineer.Slide12

Each team member will design their own prototype plane that meets the design criteria (white paper).Each team will pick one winning prototype design.

The winning design for each team will go into high volume manufacturing (HVM).Each team will make one golden image of their winning design (white paper).

Engineering Design CriteriaPlane must have at least 5 folds.Plane must be able to fly at least 5 feet.

Game Instructions

Winning Design Picked & Golden Image Made in 5 MinutesSlide13

Ex: Basic Plane Model – but be creative

Work 1

Fold up in half long way.

Work 2

Fold first corner down on each side.

Work 4

Third fold of each wing on each side.

Place in finished goods inventory.

Work 3

Second fold of wing in each side.Slide14

Teams picks their winning design.

5 minutes to test, discuss and select winnerSlide15

Day 1 RecapKey WordsSupply Chain – 4 Key Areas

STEMPrototypeMass ProductionWIPMetricsKey Learnings?Slide16

WELCOME TO DAY 2

Lean Paper Airplane Game

Grades 6 - 8Slide17

Day 1 RecapKey WordsSupply Chain – 4 Key Areas

STEMPrototypeMass ProductionWIPMetricsSlide18

Day 2: Game Day!Today’s focus areas:

Assembly Line ManufacturingMetricsTeam Set Up

Get back into your original teamsEach team member will have 3 minutes to create a replica of the design win from Day 1The “Best” replica will be reserved as the “Golden Image” for quality validationSlide19

Group and MaterialsGroup:

4-6 Manufacturing Engineers1

Quality EngineerMaterials:Paper Sheets for making planes (8 ½ x 11)Unique color paper/team recommended

PencilsScoring sheetsTimerSlide20

Round 1:In looking at our historical data, we see that our customers have been wanting us to build more and more planes each month. Management has decided that demand is probably going to increase substantially in the month of October. We want to be sure we can meet this increased demand while making money. Each plane sells for

$20.00! To be safe, we will make as many as we can.

How many Planes should we make?

Month

Demand

May

7 planes

June

9 planes

July

12

planesAugust15 planesSeptember20 planesOctober?Slide21

Goal: make as MANY airplanes as you can.

Manufacturing Engineering Team – all members must have unique roles and must repeat their step for each plane. As soon as you finish your step pass it to the next person as quickly as possible; if they are working on another one that’s okay, set it on their workstation and keep going with your step!

When the plane is complete the last production engineer will give it to the quality engineer.Quality Engineer

Will visually inspects each plane against the Golden Image: pass/failWhen the Clock has Stopped:Quality Engineer will test passing planes and calculate team metrics.

Each plane sells for

$20.00

and the WIP cost is

$5.00

/plane

Winning Team:

The most quality planes

at the end of the round

Have fun!Push Method-Round 15 minutes!Slide22

Time to do a flight test!Move to your team’s test area

Test only the planes that pass visual inspectionKeep track of the # of planes that pass the 5 ft. flight test. These are “good” planes.Complete your team’s metric sheetSlide23

Round 1: Metrics

Metric

Metric

Definition

Round #1

Round

#2

# Good

# Planes

built correctly (Flyable and pass visible inspection)

% Good

# good

planes / total planes built

Average

Lead Time

time

it took to build good planes / total good planes built

WIP

# unfinished

planes

Productivity

# good planes /

# Engineers / 5 minutes

WIP cost

#

of unfinished planes x WIP cost

Profit

(#

Flyable planes x Sales price) – total WIP costSlide24

What did we observe in Round #1?Were there any problems?Did any planes build up at a certain location? (bottleneck)

Were there any quality issues?How would you make the next round better?Slide25

What is LEAN?Steps to drive process efficiency by eliminating waste

Waiting

Unused Talent

Extra Processing

Excess Motion

Excess Inventory

Transporting

Overproduction

DefectsSlide26

Lean Method-Round 2

For this round, your goal is to maximize profit without sacrificing the quality of the planes. Excess WIP is a problem – we don’t want any. Engineering Team – take two minutes to reconfigure your teams to support your “LEAN” process.

There will now be a staging area to prevent overproduction. Each person on each team will get a post-it.You will only be allowed to produce your part of the plane when your post-it note is not covered by WIP.

Quality Engineer will enforce these rules.Once time is up…Quality Engineer will inspect your planes and calculate your metrics.

Sales price for each plane is $20.00

WIP cost per unit is $5.00.

5 minutes!Slide27

Time to do a flight test!Go back to your test area“Good Planes” = those that can fly > 5 feet.Slide28

Round 2: Metrics

Metric

Metric

Definition

Round #1

Round

#2

Good

# Planes

built correctly (Flyable and pass visible inspection)

% Good

#good

planes / total planes built

Average

Lead Time

time

it took to build good planes / total good planes built

WIP

# unfinished

planes

Productivity

# good planes /

# Engineers / 5 minutes

WIP cost

#

of unfinished planes x WIP cost

Profit

(#

Flyable planes x Sales price) – total WIP costSlide29

Round 2: Follow-up Which production method would you choose for your company? Why?

Which team made the most profit?How did the changes we made with resource-leveling and WIP change our metrics results? How did our quality improve?Did you see any areas where STEM was involved?Slide30

Activity SummaryWe learned about Supply Chain using Paper Airplanes!

SourceMakeDeliverReuse/RecycleWe learned about Science, Technology, Engineering & Math too!

Science: Optimize your paper airplane flight distanceTechnology: Mass Production of AutomobilesEngineering: Improving the production of paper airplanes (LEAN)Math: Calculating MetricsWhat else did you learn today that was new?

Did you have FUN?Slide31

Please…RECYCLE ALL PAPER PLANES AFTER ROUNDS ARE FINISHED (can bring to younger students, or recycle)Slide32

Round 1 Discussion Aide: Page 24Positive

: Cost per unit goes down as profit goes upNegative: Overproduction and excess WIP is costly and wasteful.Items to consider for additional discussionCompare winners based on profit

Who would the winner be if each WIP cost $5?What would happen if the customer suddenly demanded a change or a different product?What if October demand dropped to 3 planes?Who would be the winner each plane that had to be scrapped cost $5?Does the overproduction seem wasteful if we don’t need it?

Is making the most airplanes the correct incentive for workers?How can we better control WIP?How does this type of process impact quality?Slide33

Classroom Set Up

Team #1

Table

Team #3

Table

Team #2

Table

Team #4

Table

Front Of Class/

Power Point Display +

Whiteboard Area

Team #2

Test Flight Wall

Team #3

Test Flight Wall

Team #1

Test Flight Wall

Team #4

Test Flight Wall

5 ft

.

5 ft

.

5 ft

.

5 ft

.Slide34

List of materials Needed for 1 class of 28 students (4 teams of up to 7 students)~300 sheets of paper* (or 1 ream)4 pads of post it notes (any size)

4 calculators (or smart phones with calculator)5-10 pencilsAbility to display a power point in the classChalkboard & Chalk, dry erase board & markers, or flip chart + marker4 sets of 50 small lightweight stickers (stars, other) each set a unique color

6 metric sheet print outs – slide 36 (includes 2 spares for mistakes)List of materials Needed for 1 team of up to 7 students

~75 sheets of paper* 1 pad of post it notes (any size)1 calculator (or smart phone with calculator)1-2 pencils 1 set of 50 small lightweight stickers (stars, other)

1 metric sheet – slide 36

*

Use standard copier paper (lightweight) to aid in ease of folding a flight.

*Nice to have a unique color paper for each time, but not required

.

Activity Kits/SuppliesSlide35

Team Name____________________________________

Metric

Metric

Definition

Round #1

Round

#2

# Good

# Planes

built correctly (Flyable and pass visible inspection)

% Good

# good

planes / total planes built

Average

Lead Time

time

it took to build good planes / total good planes built

WIP

# unfinished

planes

Productivity

# good planes /

# Engineers / 5 minutes

WIP cost

#

of unfinished planes x WIP cost

Profit

(#

Flyable planes x Sales price) – total WIP cost