The Ichibutsu Game
Purpose The purpose of this simulation is to illustrate manufacturing operations, continuous process improvement, and JIT concepts in a way that involves participants not only in learning through participation, but also in decision-making. As a result of playing the game, participants should understand a number of manufacturing and operations JIT techniques, the interaction between these techniques, and be aware of some of the issues concerning the sequence of JIT implementation. Outline There are three production processes, plus an inspection station and a warehouse. The production flow follows only one route and all products are made on a first in, first out (FIFO) basis. Products, known as ichibutsu, come in three standard: red, blue, and yellow. These are made from Lego and Duplo blocks with the color of the base establishing the product color. Refer to the Process Sheet for the specification. The production team should make a few practice pieces before starting the first round. Make sufficient to build up the initial inventory in the warehouse. In each round, the game starts from the same initial conditions. That is, there is no work in process (WIP) and there are 4 reds, 2 blues, and 2 yellow ichibutsu in the warehouse. The customer demand in known. It is 2:1:1 for Red, Blue, and Yellow. However, the sequence of demand is unknown. The customer shuffles the demand cards at the start of the game, and then shuffles again between following rounds.
Participants Manufacturing Executives(s): Direct the strategic operations of the organization in order to ensure profitability. Master Scheduler(s): Directs scheduling of the operations in order to ensure the correct order of products is being produced. Machine Operator(s): Obtains Duplo blocks from the Store. Obtains dies from the Die Store. Measure Duplos in the dye for fit. Places measured Duplos in bin for transport by the Material Handler to the next station. Die Storeperson: Is as unhelpful as possible in giving the Machine Operators their dyes. Demands all dye pieces be removed and stacked before accepting a return. Material Handler(s): Moves product from one station to another in bins. This person must be the person who moves any object from one station to another. Assembler(s): Assembles the ichibutsu according to the Process Sheet. When finished with an ichibutsu, this person places the assembled ichibutsu in their completed bin for transport by the Material Handler. Heat Treatment Operator(s): Fills ovens with ichibutsu. After completely filling an oven, this person starts the oven and leaves the products inside for 70 seconds. After ichibutsu are removed from the oven, this person places the products in their completed bin for transport by the Material Handler. Quality Inspector(s): This person inspects for quality of the ichibitsu. They will look for proper assembly and for defective parts. Warehouse Manager(s): This person stores finished goods and delivers product to the customer when demanded. Customers (2): This person demands orders from a team. They read from a stack of order cards and demand an ichibutsu color every 15 seconds. If product is received immediately, it is considered on-time. If a product is delivered any time later, it is considered late. The csutomer records orders, on-time or late, in the Orders field on the computer. The customer may also demand quality improvements or make other arrangements with the companies. Observers, Auditors, Timers, and Spies: When not directly participating in a round, everyone should be observing their teams operations for problems in processes and for methods of improvement. These people should benchmark the competitors processes for innovative ideas. They should also calculate rates of customer demand and rates of production such as throughput time, cycle time, and takt time.
Layout Each team will have a straight- line production process for the first round. The process begins and ends with a customer demand signal. The workstations will placed as follows.
Game Layout Machine Center
Assembly
Heat Treatment
Inspection
Warehouse
Customer
Process Each ichibutsu is built according to the following process sheet.
Process Sheet Red
Blue
1 large red Lego
1 large red Lego
1 large yellow Lego
1 large white Lego
1 small yellow Lego
1 small white Lego
2 small red Legos
2 small blue Legos
1 large red Duplo
1 large blue Duplo Yellow 1 large white Lego 1 large blue Lego 1 small white Lego 1 small blue Lego 1 small yellow Lego 1 large red Duplo
Profit Teams will compete on the basis of who can achieve the highest profit levels. Profit is a function of several variables: Factory overhead costs: The number of desks rented. Labor costs: The number of employees on the payroll. Materials costs: How many Duplo blocks are purchased and in what quantity. Work in process (WIP) costs: Charges for having too much WIP during an audit. Finished goods inventory (FGI) costs: Charges for having too much FGI during an audit. Revenues: Earnings differences due to missed orders or due to late deliveries yielding less revenue than on-time deliveries.