1. Paper Planes Paper Aeroplane Simulation

2. Session Outline Setup a factory to make paper aeroplanes Run the factory and record performance data Analyse the data to identify area of improvement Implement changes Re-run the factory and record performance data Compare differences between Run 1 and Run 2. Discuss results. Compare Aeroplane factory with real factory.

3. Equipment & Resources Material 60 sheets of plain paper 20 sheets of punched paper 10 sheets of coloured paper 2 stop watches 1 calculator Flip chart 2 markers (different colours) People 4 Operators 1 Material handler / Forklift Driver 1 Factory Manager / Superintendent 1 Customer 2 Timers

4. Preparation 1.Allocate tasks 2.Preload stations with work Station 1 – 1 x unfolded, 1 x fold #1 Station 2 – 1 x fold #1, 1 x fold #1+2 Station 3 – 1 x fold #1+2, 1 x fold #1+2+3 Station 4 – 1 x fold #1+2+3, 1 x completed Fold # 1 (Op 1) Fold # 2 (Op 2) Fold # 3 (Op 3) Fold # 4 (Op 4) Completed

5. Run 1 - Rules 1.Building and moving must be done in lots of 3 off ONLY. 2.Once the factory is running smoothly a coloured sheet of paper will be introduced. This piece will be timed through the system. 3.Production will stop when the coloured plane is delivered to the customer. 4.Factory layout must not be changed before or during Run 1 5.Fill out Chart with collected data MeasurementRun 1Run 2 Lot Size WIP Throughput (Lead) Time Total Run Time Deliveries (to customer) Number of people Space Productivity (units/person/minute) Quality Comments

6. Run 1 - Discussion 1.What was it like to work here? How did it feel? 2.Were there any bottlenecks? Where? 3.What things could be changed? 4.Other comments?

7. Run 2 - Preparation 1.Layout a new factory addressing the issues raised. 2.How can the WIP be better managed? 3.Start Run 2. Fill in Chart with data collected. MeasurementRun 1Run 2 Lot Size WIP Throughput (Lead) Time Total Run Time Deliveries (to customer) Number of people Space Productivity (units/person/minute) Quality Comments Customer OP #1 OP #2 OP #3 OP #4 Raw Material “Kanban” square

8. Run 2 - Discussion 1.What was it like to work here? How did it feel? 2.Were there any bottlenecks? Where? 3.What is the maximum WIP? 4.How does the data compare to Run 1 5.Did any Operator work faster or harder? 6.What things could be changed? 7.Other comments?