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www.st-andrews.ac.uk/lean
Lean Lego
Marvellous Models, Inc
Overview
This activity will give the participants the opportunity to:
Participate in a process Evaluate the process Identify wastes that can be eliminated from the process
o Transporto Inventoryo Motiono Waitingo Over productiono Over processingo Defectso Skills
Redesign the process to eliminate wastes
Measure time savings in redesigned process
This will allow participants to experience how Lean can be applied toprocesses, and appreciate the benefits of using a Lean approach.
In this activity, there are 5 different roles: Stores Construction 1
Construction 2 Supervisor/Quality Control
Customer.
Participants take on one role, and are given some guidance notes ofwhat is involved in that particular role.
The KPI for the supply of models to the customer is 5 minutes permodel.
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www.st-andrews.ac.uk/lean
Lean Lego
Marvellous Models, Inc
Instructions: Stores
Your task is to supply the bricks as requested. Your store, consistsof hundreds of Lego bricks in different colours. When one of theconstruction sites receives an order, they will come to you and askyou to supply the bricks required. Put the bricks that they ask foron one of the paper plates and give them to the construction teamas required. There is a form to be completed on supply. Theconstruction team will give this to you to fill in as appropriate andreturn with the bricks.
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www.st-andrews.ac.uk/lean
Lean Lego
Marvellous Models, Inc
Instructions: Customer
You have been given a supply of order forms to enable you torequest some Lego models from a catalogue. You can choose whichmodels you want, and pick the colours you would like them in. Youneed to complete one form per model, and take the orders to theSupervisor/Quality Control. Please note the time of your order onthe form. Once the models are complete, they will be returned toyou and you should note the time of delivery on the form.
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www.st-andrews.ac.uk/lean
Lean Lego
Marvellous Models, Inc
Instructions: Construction 1
Your role is to construct the non-animal models from Lego bricks.You will receive orders for specific models from your Supervisor.When you receive an order, you need to visit Stores, give them theorder form and collect the right amount of bricks. You then need toreturn to the building station and build the model. Completedmodels should be taken to the Supervisor who will do a qualitycontrol check.
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www.st-andrews.ac.uk/lean
Lean Lego
Marvellous Models, Inc
Instructions: Construction 2
Your role is to construct the animal models from Lego bricks. Youwill receive orders for specific models from your Supervisor. Whenyou receive an order, you need to visit Stores, give them the orderform and collect the right amount of bricks. You then need toreturn to the building station and build the model using theappropriate template you have been given. Completed modelsshould be taken to the Supervisor who will do a quality controlcheck.
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www.st-andrews.ac.uk/lean
Lean Lego
Marvellous Models, Inc
Instructions: Supervisor/Quality Control
You will receive orders for Lego brick models from the Customer.You need to check the order then pass it onto the appropriateconstruction team. Construction Team 1 build the non-animalmodels, and Construction Team 2 build the animal models. Thecompleted models will be returned to you for a Quality Controlinspection, where you will compare the model with the appropriatetemplate. If you are happy with the quality, then the model shouldgo to the Customer together with the original order form. If themodel is not correct, it should be returned to construction to fix
before passing onto the customer.
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www.st-andrews.ac.uk/lean
Marvellous Models Inc. Order Form
Model Colour
Date ordersubmitted
Time ordersubmitted
Customer Signature
Marvellous Models Inc. Order Form
Model Colour
Date ordersubmitted
Time ordersubmitted
Customer Signature
Date orderreceived
Time orderreceived
Customer Signature
For Official Use Only Time InitialParts Supplied from Stores
Model Constructed
Model pass QC
Date orderreceived
Time orderreceived
Customer Signature
For Official Use Only Time Initial
Parts Supplied from Stores
Model Constructed
Model pass QC
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www.st-andrews.ac.uk/lean
Marvellous Models, Inc. Product Catalogue
Please feel free to browse our catalogue below, and once you havemade your selection, complete one of our order forms.
Model selection:
Aircraft carrier Duck Robot
Ideal forthose timeswhen only a
boat justisnt enough
That perfectmechanicalhelp around
work andthe home
Chair Aeroplane
Perfect forwhen sitting
around isthe optionof choice
Want to getsomewhere,
and fast?You need to
fly!
Dinosaur Horse
Arrrgh! Itsa scary
dinosaur!
Didnteveryone
want a ponywhen they
wereyoung? Getyours now!
Colour selection:
Blue Green
Purple
Yellow Orange
Pink
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www.st-andrews.ac.uk/lean
Marvellous Models, Inc. Construction Instructions
Aircraft carrier Components Duck Robot Components
14 2
3 7
10 7
Chair Components Aeroplane Components
16 0
0 2
12 5
Dinosaur Components Horse Components
410
36
4 6