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Round 1 (Traditional) Round 2 (Some Lean) Round 3 (Lean)

SIMULATION. Round 1 (Traditional) Round 2 (Some Lean) Round 3 (Lean). Orientation. to the Paper Boat Factory. Paper Boat Factory. Paper Boat Factory. BBWS. Paper Boat Factory. WBBS. $2.00/person/shift. Labor cost:. Facilities cost:. $10.00/table/shift. Paper Boat Factory:. BBWS.

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Round 1 (Traditional) Round 2 (Some Lean) Round 3 (Lean)

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  1. SIMULATION • Round 1 (Traditional) • Round 2 (Some Lean) • Round 3 (Lean)

  2. Orientation to the Paper Boat Factory

  3. Paper Boat Factory

  4. Paper Boat Factory BBWS

  5. Paper Boat Factory WBBS

  6. $2.00/person/shift Labor cost: Facilities cost: $10.00/table/shift Paper Boat Factory: BBWS Sells for $4 Materials cost $0.50 WBBS Sells for $4 Materials cost $0.50

  7. PBF • Sales Representative Processes “Customer Order” • Production Scheduler Generates “Factory Order” from forecast • Kitter(s) Organizes raw materials for “Factory Orders” • Material Handler Moves product between ALL workstations • Folder I Initial folding: Blue • Folder II Initial folding: White • Folder III Final folding : Blue • Folder IV Final folding: White Assembly • Inspector Assures Quality • Reworker Repairs failed boats • Warehouse/Ship Clerk Matches boats to “Customer Orders” • Production Supervisor Supervises production • Industrial Engineer Monitors production process • Trucker Ships products to the customer

  8. PBF Sales Office Production Control Kitting Area Shipping Dock Finished Goods Whse. Rework Area WIP Storage Folding I Blue Inspection Area Folding II White Folding I White Folding II Blue

  9. PBF Blue Paper White Paper

  10. PBF BBWS 1 piece 1 piece WBBS 1 piece 1 piece

  11. PBF BBWS 4 per batch 4 per batch WBBS

  12. PBF Production Scheduling Process Shipments to customers Customer orders (demand) Customer order forms Production forecast Factory order forms Finished Goods Warehouse

  13. PBF Promisedshipments to customers Promised shipments to customers 4 minutes after order 4 minutes after order All orders are filled “first-in, first-out” (FIFO)

  14. Paper Boat Factory • All shifts are 10 minutes • Keep busy at all times • Yell if you need parts • Handle all parts first-in, first-out (FIFO) • Only the Material Handler can move parts • Stay at your workstation • The boss is always right!

  15. Paper Boat Factory Round 1

  16. Round One: Debrief • Discuss results • How did it feel? • Relationship to real world

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