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The Big Lean Simulation Library: Simulation Catalog

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Catalog of Lean Simulations currently included in The Big Lean Simulation Library. The Big Lean Simulation Library is a free download licensed under a Creative Commons Attribution-NoDerivatives 4.0 International License.

http://thebigleansimulationlibrary.wordpress.com/

These models may be inserted into a Lean or Lean Six Sigma trainer's curriculum to dynamically show key concepts. Some models are for demonstration only, while others are more interactive or game-like.

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The Big Lean Simulation Library: Simulation Catalog

  1. 1. The Big Lean Simulation Library Simulation Catalog May 4, 2015 This work is licensed under a Creative Commons Attribution-No Derivatives 4.0 International License https://creativecommons.org/licenses/by-nd/4.0/ For information on the free download, visit: TheBigLeanSimulationLibrary.wordpress.com JerryLevasseur@outlook.com © 2015 The Big Lean Simulation Library, LLC
  2. 2. 1-1 Push vs Pull with Kanban-Office Theme: Office Ideas Simulated: Push vs Pull, Kanban, Queue, WIP, Reducing Travel Time, Delay, Impact of WIP on Quality Concepts Discussed: Defects and Kanbans, Root Cause, Clutter This simulation consists of three scenarios. Scenario 1: This shows a push office system. The first workstation produces a run of 100 documents. The second workstation processes those documents at a slower rate. As a result, the "pushed" documents add excess inventory and Work-In- Process (WIP). In addition, the first workstation experiences a quality problem after 30 documents (such as linking to an outdated database and not realizing it). As a result, about 70 defective (NIGO) documents are produced before the downstream workstation catches the problem and tells the first workstation. Scenario 2: In this scenario, we use a Pull based kanban system to process documents only when the second workstation is able to process them. As a result, key metrics for Work-In-Process and quality are dramatically improved while still producing at the same rate. Scenario 3: Travel (or transmittal) time is reduced, thus allowing fewer kanbans. All metrics are improved further. The final view shows optional discussion bullet points. © 2015 The Big Lean Simulation Library, LLC
  3. 3. 1-2 Push vs Pull with Kanban-Mfg Theme: Manufacturing Ideas Simulated: Push vs Pull, Kanban, Queue, WIP, Reducing Travel Time, Delay, Impact of WIP on Quality Concepts Discussed: SPC, Defects and Kanbans, Root Cause, Space This simulation consists of three scenarios. Scenario 1: This shows a push manufacturing system. The first workstation produces a run of 100 parts. The second workstation processes those parts at a slower rate. As a result, the "pushed" parts add excess inventory and Work-In-Process (WIP). In addition, the first workstation experiences a quality problem after 30 documents. As a result, about 70 defective parts are produced before the downstream workstation catches the problem and tells the first workstation. Scenario 2: In this scenario, we use a Pull based kanban system to process parts only when the second workstation is able to process them. As a result, key metrics for Work- In-Process and quality are dramatically improved while still producing at the same rate. Scenario 3: Travel time is reduced, thus allowing fewer kanbans. All metrics are improved further. Note – This is the same as the Office version, except with a different motif. © 2015 The Big Lean Simulation Library, LLC
  4. 4. 2-1 Batch vs One Piece Flow with Setup-Office Theme: Office Ideas Simulated: Batch, One Piece Flow, Work-In-Process, Set-Up Time © 2015 The Big Lean Simulation Library, LLC
  5. 5. 2-2 Batch vs One Piece Flow with Setup-Manufacturing Theme: Manufacturing Ideas Simulated: Batch, One Piece Flow, Work-In-Process, Set-Up Time © 2015 The Big Lean Simulation Library, LLC
  6. 6. 3-1 Takt Time and Line Balancing-Takt Sign Theme: Manufacturing Ideas Simulated: Line Balancing, Takt Time, Overproduction, Space © 2015 The Big Lean Simulation Library, LLC
  7. 7. 3-2 Takt Time and Line Balancing-Gingerbread House Theme: Manufacturing Ideas Simulated: Line Balancing, Load leveling, Takt Time, Overproduction, Space © 2015 The Big Lean Simulation Library, LLC
  8. 8. 4-1 Variation in a Push System-Office Work Theme: Office Work (Banks, Insurance Companies, Government Offices, etc.) Ideas Simulated: Variation, Queuing Theory, Push System, Line Balancing © 2015 The Big Lean Simulation Library, LLC
  9. 9. 4-2 Variation in a Push System-Manufacturing Theme: Manufacturing Ideas Simulated: Variation, Queuing Theory, Push System, Line Balancing © 2015 The Big Lean Simulation Library, LLC
  10. 10. 5-1 Batch vs One piece Flow with Transport - Office Theme: Office Ideas Simulated: Batch, One Piece Flow, Travel Time, Batch Size This model allows the user experiment with different batch sizes. They optimize batch size for different levels of transport time required. They see that to get to one piece flow, they must minimize travel or transport time. But when they do, the improvements are spectacular. © 2015 The Big Lean Simulation Library, LLC
  11. 11. 6-1 Variation in Pull System-Office Theme: Office Ideas Simulated: Variation, Pull System, Kanban © 2015 The Big Lean Simulation Library, LLC
  12. 12. 6-2 Variation in Pull System-Manufacturing Theme: Manufacturing Ideas Simulated: Variation, Pull System, Kanban © 2015 The Big Lean Simulation Library, LLC
  13. 13. 7-1 Shared vs Unshared Queue-Hospital Theme: Hospital Inpatient Unit Ideas Simulated: Shared vs unshared queues, cross-training. Concepts Discussed: Travel time. © 2015 The Big Lean Simulation Library, LLC
  14. 14. 8-1 Little's Law Demonstrated Theme: Call Center Ideas Simulated: Little's Law, queuing, Work-In-Process, impact of variability © 2015 The Big Lean Simulation Library, LLC
  15. 15. 9-1 Kanban Game – Making Robots! Theme: Manufacturing Ideas Simulated: Kanban, Just-in-Time, Variability, Work-In-Process © 2015 The Big Lean Simulation Library, LLC
  16. 16. 10-1 Cross-Training-Server Farm Theme: Server Farm Ideas Simulated: Shared vs unshared queues, cross-training. Concepts Discussed: Travel time. © 2015 The Big Lean Simulation Library, LLC
  17. 17. 11-1 Load Leveling in an Emergency Department Theme: Hospital Ideas Simulated: Load Leveling, Bottlenecks © 2015 The Big Lean Simulation Library, LLC
  18. 18. 12-1 Rework-IDEF0 Process Mapping-Mortgage Lending Theme: Mortgage Company Ideas Simulated: Rework, IDEF0, Process Mapping © 2015 The Big Lean Simulation Library, LLC
  19. 19. 13-1 Quincunx (Binomial Simulator) Theme: Abstract Ideas Simulated: Binomial distribution, quincunx, randomness, skewness Supports Six Sigma training © 2015 The Big Lean Simulation Library, LLC
  20. 20. 14-1 Distribution Sandbox This model is intended for the user to just play around with sampling from different distributions. They can see the impact of combining more that one distribution. Theme: Abstract Ideas Simulated: Distributions, Uniform, Triangular, Normal, Exponential, Gamma, Weibull, Erlang, Sampling, Bimodal, Multimodal. Supports Six Sigma training © 2015 The Big Lean Simulation Library, LLC
  21. 21. © 2015 The Big Lean Simulation Library, LLC
  22. 22. A15-1 Series vs Parallel Approvals This model examines the trade-offs between series and parallel approval processes. Theme: Office, Administration Ideas Simulated: Waste: Waiting vs. Overpruction User may change the following parameters: Arrival schedule of documents, reject rate for each of the three approval levels, processing time for each level, staff schedules for each level. The idea for this model was suggested by Bruce Fratto of GE Energy Management. © 2015 The Big Lean Simulation Library, LLC

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