Simulation: Catapult Exercise - Round 2
So this takes us into our around too all right, so this is where we say let's review the results of round one and we haven't I'm right here and we had this twenty nine inch range and all from ninety five to one twenty four all right? And we've said now in round two we're going to re shoot capture everything we need thio reduce that to six inches which tell us what six sigma if we've got a twelve inch target a two to one ratio all right, so, uh complete the issue cow a diagram that's where we take that fish bone out and we say oh uh all right uh no let's uh let's just play with that for a minute and we'll do it real time so we've got our process map let's take our fish issue cover drawing ishikawa here and let's say, uh, here we have the variation in our distance and let's start with the, uh the machine the catapult just brainstorm a couple of ideas here. What about what could we do with the machine? Stabilize it, tape it down. We got duck tape that could help. All right, we got we coul...
d sandbagged the table that could help stabilize the table so we need you know we need to stabilize the, uh, catapult we got duct tape we got the sandbag things like that okay, so we just start toe brainstorm the variables and we start to figure out ways to do something about it and play with it a little bit. Okay, we had the, uh with the measurement system what could we do, teo to know where the ball lands with more precision we is you know what? We get this get this aluminum foil you know what if we put the aluminum foil out on the floor at least in a little section here and when the ball came in what is it pinned it that would be interesting but uh let's play with that let's test that thing so we've got you know, the foil here to give us a better reading on a, uh solving this problem uh, what other ems did we have? We had uh you know, manpower people what are some things we could do here to make sure that we're ah, we're all basically doing it the same way maybe in s o p standard operating procedure so we said all right, we're all gonna pull it back to a set point, by the way let's go back to machines or anything we could do with the machine to create a set point right liver is gonna go down there so come up with some kind of stopper that puts us at thea that puts us right there at that one seventy seven maybe you know maybe something like this little bottle cap or something well along with some duct tape or uh coins people I mean people come up with all kinds of stuff all right but we could come up with a stopper to poke a yolk the machine so now I can actually shoot it with one I closed both eyes closed you know um but let's talk about um method okay, what about our method we can couple that with our s o p so we're all using a standard method but do we have a standard ball load method? I think this ball is perfectly surround and symmetrical or maybe there's a reason there's a dot on it maybe we want to load the ball the same way every time variations funny it'll creep in just about anywhere so the ball we might want to load it in with the dot face and out of that that facing in butt load the ball a certain way we might want to have somebody else load the ball all right as opposed to the shooter incidentally, uh what about this beth about removing the rubber band and put it back again? Is that really necessary? Does that really add value? We don't you know, to we could run experiments on it but one thing we know about the rubber band is that it in fact does take a little time to adjust. So if you think about this if you watch that pen when I pull this back, you know, watch that pin real, click carefully and tell me when it stops moving. If I pull this back it's actually going up still, you see that? In other words, the rubber band is taking time to to adjust. So if I pull it back for two seconds and shoot it, all right, jane pulls it back for five seconds and shoots it. Kimberly gets up here, and just the time that we actually hold it back could actually introduce quite a bit of variation. So maybe our standard methods says we'll pull it back. Count to three. You know, he's in a pacer clock and release. So you'll notice that in a lot of world class systems, timing is built into the standard work. Okay, amazon, you got forty eight hours to confirm. You have seven days. Teo deliver it's time, because time based management is part of the whole lean system so we could consider time. Alright time here. Um, we've got things like, uh, miscellaneous or mother nature is there is, uh, the carpet affected does the wood effect it was the air temperature effect that things like that, um I won't spend a lot of time on that right now, but I will say that when you put the catapult on carpet it actually makes a big difference versus if you put it on a hard surface all right you do worse let's put it that way and, uh, material so we've got material here so with material we got that ball we said well, maybe we should load that ball iss the same way every time we've got that rubber band and maybe we could uh link that with time to pull it back count to a certain amount we could release it on dh each time and redo it I'd still recommend that we use time okay to figure it out but I mean tio pace it everything so wade play with this and we'd spend more time playing with it and uh and thinking through every everything that we can think through as far as all of these things this is where we partitioned the variables is it controllable or no ways all right, can we control this so let's go you know can we, uh can we control essentially we're knowing where the ball lands could we could we uh could release that is a controllable let's put the oil down there let's zeno where it lands can we stabilize the catapult and control it to a large extent with duct tape with sand sandbagged things like that could we control our pullback point so that it's always one seventy seven and we don't get those long drives so to speak and things like that can we control the way everyone shoots it using a standard procedure that everybody follows and training okay so we're actually going in here and we're saying these air these ex variables the is it input variables and if we can control these things we can control the loading process we can control again with the s o p we can control the time we pull back and release all right we can try again control the ball load control of the rubber band to some extent through our counting so we start to say look we've got a lot of variables in this equation most of which went uncontrolled in the first round that propagated into all kinds of unpredictable performance unacceptable performs costly performance and so we're going we're not going to make it perfect necessarily but we're going to make it better we're going to make it better fast and we call that kaizen so we're going to guys on this reshoot the catapult now all right and let's just put together a little s o p a will stand out standard operating procedure again keep it simple so our s o p standard operating procedure will be uh first thing we're gonna do we're gonna set up and stabilize everything so we're goingto uh you know pull back to the stopper not we in aa kai's an event where we actually have it had a little more time and were playing around with us we experiment with our team and say well what's the best pull back is it the one figure pull back is it you know you could see what other teams have done with this catapult there's red dots on both sides of this team said you know you're going to hold the two red dots like this and pull it back and shoot it that way uh you know there are teams that have done little clever things like this where they've said uh duct tape is so handy we could take a duct tape in this case and we could create a little a little pull back like this because you want his little friction is possible you know when you release it so long as I've got strong fingers toe to grab that and hold onto it could even make it just a little bit uh uh a little bit longer okay so now we've got this this little tale that we can grab on and just pull it back in that way we all know we all shoot at the same way so we could we could explore experiment a little bit with different techniques but so we're going to pull back to the stop for uh you know, holding uh uh tail so to speak uh we're going to count to three one thousand so to speak just to keep a peso one one thousand two one thousand three one thousand shoot we could even control that even more by having a counter so we're going to have somebody who counts the same way every time one one thousand two one thousand three one thousand release or we could count it ourselves but now we could be introducing more variation so what do you think should we have ah one person counted out so uh so we have a second person count to three all right three seconds you gotta load the ball so we haven't released yet but in terms of our sequencing we could step one step two types step three so the next step here is that load the ball so we could have that same second person who's counting or a third person um what do you want to do this second person or third person okay, well I think that with the dot all right there you go that facing up so it was a dot on the ball so we're gonna have this second person one one thousand two one thousand three one thousand also loading the ball and saying shoot so one one thousand two one thousand three one thousand shoot and we the ball's loaded we release quickly so we simply let go of that little pull back all right we have then uh measure uh uh, king, you want to call it that in the aluminum foil? So where did it? Where did it ping? And we can lay the foil out there. In fact, what we could also do is get some of those little dots. We're not done with the dots just yet. So we've got a few more of those dots around here when the ball comes. Instead of having this big tape measure out here in everyone's way, the ball comes in, hits a hits the foil, we put a little yellow daughter, little red dot down there, we know exactly where it hit next shot next shot. Now, at the end of all of our shots, we've got eighteen shots are range could be a simple is yeah, but we don't need this thing hanging out all over the place. You'd be surprised some kaizen teams when they're doing this, they run the foil all the way from the front to the back. They got the tape measure out here and it's like, really, we just finished the whole lesson on lean and what is it, what's that all about? So we have to know think carefully about what are we looking at here, all right, so we're going to measure the ping and and market, you know, and then, uh, at the end, of course, we're going to record the data. So from a shooter perspective, we saw here's your process. So we've got new people coming into our company, we want to train him in a standard approach here's our standard method, you're gonna pull this back, so take it to the tail, so we have to create the by the tail, so we have to create this stopper, so that could be something as simple as we're gonna. You know, we're going to put something back here that stops it at one seventy seven. All right? And what? We need something, uh, take it up just a little bit more post its they're also very handy. So let's, go ahead and just, uh, a couple more post its will do that and we poke a yoke it at one seventy seven. We get our handy duct tape out here. What? You know how my home how many ways wait, there could be issues so many very well, there are here's the thing you know what, you think this is a silly little game I've got. I've got video of ceos of multi billion dollar company shooting this thing in high five they're saying, when they get so mean, people take this, it seems like a silly little illustration but variation is killing some companies and they can't figure it out trying to, you know, trying to pride world class service and the variation is just eating him up. So this is a simple way by the way, these types of exercises, the experience, the experiential exercises and things to remember for a long time, you know, it's like confucius said what I hear, I forget what I see I remember it's what I do, I understand by doing this stuff, you know, I get people talking about catapults decades later, I remember that catapult thing you did and, uh so here we just, uh, throw a little duct tape on here and by the way, you know, I'm walking you through this particular kaiser and if you will, just because of the nature of this course, but in a workshop, you could have teams break out and think that this on their own, okay, so we've got that right now, so the idea is going to be all right, I'm gonna be shooting this, all right? My process let's, just check it. I'm going to grab this here, pull it back to the stopper somebody's going to count to one one thousand two, one thousand three, one thousand while loading the ball dot facing up and say, shoot, I shoot it it's going to come in and ping the theologian of oil or somebody's gonna put a dot on it and or a mark of some sort and then we'll measure at the end okay and that's our process now we still have one problem and that is that this catapult is um sliding all over the place so welcome duct tape and this is where uh you'd say well let's let's strap this thing down and uh tim the tool man would just love this would be like how come I don't get to do that kind of stuff you do, tim all right, we could say lots of ways to fasten this this thing down so we we could even have somebody from our team while someone is shooting you know, just for a little added support we have maybe one person just hold this thing down you don't want to get your finger and there were could get pinched but that that would help and it would also help the sandbags not really that heavy so that's not gonna necessarily, you know, hold this in place um you know, so if we do things like this just to fasten it down, we know what we're doing here is just simulating we're stabilizing our process so that, uh you know, we're taking off the variation I'll see what happens now when I just pull this back and shoot it so you can still see the table moving that's variation okay and each time if you look down it's it's table's moving it's jumping forward you know just uh you know a mill you no not even a quarter of an inch so we'll throw that on there and see what happens it's still jumping so if somebody went like this don't get shot in the head but uh somebody just like that it would certainly help so that's the idea of stabilizing our process and doing it very quickly so we could certainly uh you certainly tape it down fasten it more but let's just see what happens with that so we've got that and we say all right where the ball's going to come shooting over here let's go ahead and pull out some oil and let's assume that we're not gonna take any more uh maybe space than this we don't know yet where exactly it's going to land but uh theo this out something like that not we could move the carpet now we don't move the carpet during the game you just introduced more variation so let's uh I'll take that down if we're in good shape I'm gonna go out and just take a shot to demonstrate this and you put a foot here and I think it's gonna miss the foil just because it's uh it's aiming a little more this way try that and let's just see what happened so pull back load ball dot up one one thousand two one thousand three one thousand ok, so we can see where the ball landed there's a big dent right there so maybe what we'll do is pull this whole carpet variation st duct tape the boil down not to add any more variation to duct tape yeah, no, I think that once we know roughly where it's gonna land that's a great idea so well that will duct tape the foil just so it doesn't move around a little bit there and you guys can get ready to start shooting so we're going to shoot here and wrap up this session okay and did we have dots or should we just use this black marker? Okay, I just yeah, if we have dots down there in that lower ben if we dio we can use the dots there's dots there's some does not think suitors we're still alternated shooters because we have to do so let's go ahead and line up let's follow the same sequence so kurtz you're shooting first, right? Yeah, you were shooting first before and let's just go ahead and yeah, and uh if you would look yeah, if you could if jamie could hold and then uh jane you shoot last so you could hold through the whole round and then when you shoot kurt, maybe you hold you know so find a place to hold it down over two measurement now but if the holder also counts to three and loads of balls that you think too much alright that counts okay and you're gonna count to three one thousand and load the ball dot facing up so you'll be the ball loader all right okay it's going to count load the ball so okay you uh you will go second toe last so jane will go last you go second celesta everybody else will shoot in the meantime okay? And uh susan you're going to retrieve the ball ok? And then um I can go ahead and just market I'll play customer market with either the marker the dots when the ball comes landing in here and we'll uh we'll see what happens. Okay, so our procedures everybody follows the same thing pull back to the stopper holding the tail kate is going to count to three one thousand while loading the ball dot facing up say shoot you let you release and uh I'm going to measure where it pings and capture the capture of the data all right, so I wanna get back to my data sheet okay, wait, we're ready okay, game on do you need the procedure? You guess? Okay one one thousand two one thousand three one thousand shoot it all right got it here we go, here comes the ball one one thousand two one thousand three one thousand shoot all right, one inch apart one one thousand two one thousand three one thousand shoot okay longer that time all right, who's next cat e one one thousand two one thousand three one thousand shoot okay, one one thousand two one thousand three one thousand shoot one one thousand two one thousand three one thousand shoot all right, carol is next. Glad one one thousand two one thousand one one thousand two one thousand one one thousand two one thousand three one thousand shoot a little short you know we could have something else grab the ball too if that helps one one thousand two one thousand three one thousand shoot alright it is okay who's next yeah one one thousand two one thousand three one thousand shoot all right one one thousand two one thousand three one thousand shoot, huh? Thie exception of three shots we have a one inch range with the other three it looks like about four inches total. We'll measure it later, but one one thousand two one thousand three one thousand shoot now that one came up a little short because it was being held before you started counting to three that's that rubber band that'll do that teo okay who's next wei have a different counter this time is gonna change you can still count count okay alone one one thousand two one thousand three one thousand ok count and catapult multitasking now okay one one thousand two one thousand three one thousand just looking to eliminate waste from earlier thinking she do huge up to jobs that's right? See it's ah leen thinking one one thousand two one thousand three one thousand okay, so who's next gene that's uh that's gonna be it all right one one thousand two one thousand three one thousand shoot okay, one one thousand two one thousand three one thousand shoot one one thousand two one thousand three one thousand shoot the same so is that everybody way? That's everybody so we have one more little test now, um are arranged by the way if you want the data is five inches, so we had a twelve inch speck from the customer. We had a six inch voice of process. We did better than six sigma always talked about a two to one ratio, so a six inch range with a twelve inch target would have been a two to one ratio. Translation six sigma we did slightly better than that with again a basic understanding of a few fundamental tools. He was an issue calleigh using process mapping, getting aligned and figured out a clever way to use creativity before capital and ah what we haven't done yet, though, is demonstrated that we could shoot it into a cup. So now I would like you to pick one of your shooters. And again, I didn't capture each shooters. Data point up here. It was easier just to put it down here and then measure at the end range coming in from our chat. Like, why didn't you measure it the second time around? But we're just looking for the rain train. That's, right? So I leaned out the measurement process. Now I could've I could've loaded this into an excel spreadsheet shot. I could I could have done in a number of different ways that could have loaded it up here like I did before. But all I was really asking for and round, too as well as around one was the range. So a quick way to get the range is just to do it the way we did it. Uh, but now, if I wanted to calculate average and I would have to now up from here, I could actually run my tape measure out. I could calculate from the markings exactly where each shot was. Different ways to capture the data but what I'd like to do is randomly pick or just pick a volunteer from the team any one of you if the process is truly robust now toe variation of love with operators pick one shooter you get one shot using your standard process to put it in this cup and I'll hold the cup okay had an angle to I won't move it but I hold the cup there let's see if you can pass the true sixty six sigma shoot the ball in the cup test before we closed for today so who wants to shoot? I know susan we love to try this but you're going to shoot it same process oh, way need a holder? We need a counter, kate you could count and load susan's going to shoot and then we have to murphy proof this which means I have to use your process and see if I can shoot it into a cup into the cup so we'll start with you. This is a test and I'll just put this right down here about where you you were landing it based on the data. Alright, one one thousand two one thousand three one thousand oh, wait, that was dark, so now I need somebody hold the cup for me, all right, curt, you want to come up here and you could see where basically to do it just told it at a kind of an angle just because of the ball coming in now I've been I've been following your process I'm going to give you the ball you loaded for me right and I'll have to do is pull it back and let it go right one one thousand two one thousand three one thousand ships o run of the room uh alright a different angle you know what let's uh let's look att just to wrap up this session a little bit let's look at what we did we went from a twenty nine inch range uh to a five inch range that's a significant improvement is it perfect? No, but it's better and again the whole idea kaizen is better not best let's get after let's do it quickly let's not take six months or a year toe improve some obvious things in our process we could do that relatively fast and by doing it fast people start to realize you know what? We really are serious about making positive change were really serious about kaisa and it gets exciting and it's that same energy that we uh we were talking about earlier so we've captured our data we could plot our data now using a history graham we could make a make it visual just imagine this is a little history graham with little stacks you'd have this you have this little normal distribution right here because you can see most of the shots if you look at it closely. Most of the shots you right in the center so we had a little a little normal distribution going on right there we could plot it on a run chart so each shot you know is this plodded along a run short then we could start to play with that data to interrogate it tto learn from it run some numbers, run some you know, statistical process control and uh and then uh gain more knowledge from it. Okay, take it to the next step so the next thing we're going to do some of you are already observing hey, we could do this. We could do that. We could change more that's exciting when people start saying, you know what let's make more change as opposed to let's resist it or hear it we go into the sea and andy make and this is where we get into things like standard work, visual control, statistical process control is an example. Ah visual control control charts five s which we covered earlier really organizing everything. So um nothing's in the way that we don't need that kind of thing mistake proofing we've covered that in documentation just this is in your deck standard work system says we break it right down to things like sequences steps time we count to three. What we just did is an illustrious, simple illustration of standard work. So it's, we were all doing it the same standard way. All right. And that's taken variation. Now we can describe the steps we can describe is this emanuel activity is an automatic activity. Are there any hazards we should be aware of? We can actually flow chart it. So we'll create a little document. That's, justice it's like a recipe it's a simple template that shows us here's how we do this. This work here, thanks to be conscious of it, here's. Some areas where we need to do a quality check or we need to document something, okay? Or, you know, we've got a hazard. So this, um, heads up little code you can use to customize it. But this is a standard worksheet that everybody's trained on to make your process more robust to human variation. Visual controls again, these air things very, uh, you just visually keeping think of scores, you know, uh, scoreboards. And we've got those examples of those right here a creative life right now talk a little bit more about visual controls and things like that. Another segment five s we should we opened yesterday session one with some five s, but this is that's, the way the self explain where everything should be and, uh, is it in the right places that, uh, if we got a good control system in place, all right, and there are the five s's these air, any material, and we covered these earlier, so five s would be built into this is part of our control system, and, uh, they were back to aa quote we've already seen before as well what aristotle said we are what we repeatedly d'oh excellence is not an act but a habit it's, not a one time thing. We've created a habit here, their standard work through this particular kaizen weaken habitually, now hit the target and weaken kaizen it further. But now we've got a very predictable process that we can share. Um, I'll tell you what, it's, a game winning strategy. When you have game winning strategies, you start winning games, boy, talk about morale going up and word of mouth and raving fans and advocates and promoters and business growth. That's what that's, what this is really all about.