Manufacturing Lego (TM) Pyramids
Yellow Belt students "manufacturing" Lego (TM) pyramids are very intense (from our March 27-29, 2012 class). We ran the process simulation across three rounds. In the first round, the five student teams collectively delivered 25 pyramids. After training and the application of process improvement techniques, production skyrocketed. In round three, the same five student teams delivered 245 pyramids. Although we fell short of the 250 pyramid goal, we were successful in eliminating waste, reducing process variation, and managing the system constraints. Increasing production in a simulated environment by 1,000 percent is difficult but achievable. Now, we've just need to take the lessons back to the real world and apply them.