Lean Paper Airplane Game Grades 6 - 8

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Today’s Objectives Create Awareness of Supply Chain Experience how Supply Chain & STEM work together Have fun!

STEM Science Technology Engineering Math

Supply Chain Source Make Deliver Reuse/Recycle

Supply Chain and STEM make things happen! Source Make Deliver Reuse/Recycle STEM Science Technology Engineering Math +

Could this process be improved? Is that how cars are made today? Mass Production Producing large amounts of standardized products in an assembly line Example: Ford’s production line Think “Lean” – do you see any ways (small or big) to improve the process? Could this process be improved? Is that how cars are made today?

Work in Process (WIP) Unfinished products in a production process.

Metrics Measurement of Performance or Product Quality Time Cost

Paper Airplane Competition

Team Setup The class should divide into teams of about 5-7 students/team. Each team should be seated at their own table – and separated from the other teams. Ensure there is sufficient room to flight test – launching the airplanes towards a wall (away from students, and not towards other teams). Each team member starts as a design engineer. The STEM focus on this activity is math intensive, and show the relevance of math in the cell phone industry

Game Instructions Engineering Design Criteria Each team member will design their own prototype plane that meets the design criteria (white paper). Each team will pick one winning prototype design. The winning design for each team will go into high volume manufacturing (HVM). Each team will make one golden image of their winning design (white paper). Engineering Design Criteria Plane must have at least 5 folds. Plane must be able to fly at least 5 feet. Winning Design Picked & Golden Image Made in 5 Minutes

Ex: Basic Plane Model – but be creative Work 1 Fold up in half long way. Work 2 Fold first corner down on each side. Work 3 Second fold of wing in each side. Work 4 Third fold of each wing on each side. Place in finished goods inventory.

Teams picks their winning design. 5 minutes to test, discuss and select winner

Day 1 Recap Key Words Supply Chain – 4 Key Areas STEM Prototype Mass Production WIP Metrics Key Learnings?

WELCOME TO DAY 2 Lean Paper Airplane Game Grades 6 - 8

Day 1 Recap Key Words Supply Chain – 4 Key Areas STEM Prototype Mass Production WIP Metrics

Day 2: Game Day! Today’s focus areas: Assembly Line Manufacturing Metrics Team Set Up Get back into your original teams Each team member will have 3 minutes to create a replica of the design win from Day 1 The “Best” replica will be reserved as the “Golden Image” for quality validation

Group and Materials Group: 4-6 Manufacturing Engineers 1 Quality Engineer Materials: Paper Sheets for making planes (8 ½ x 11) Unique color paper/team recommended Pencils Scoring sheets Timer

Round 1: How many Planes should we make? In looking at our historical data, we see that our customers have been wanting us to build more and more planes each month. Management has decided that demand is probably going to increase substantially in the month of October. We want to be sure we can meet this increased demand while making money. Each plane sells for $20.00! To be safe, we will make as many as we can. Month Demand May 7 planes June 9 planes July 12 planes August 15 planes September 20 planes October ?

Push Method-Round 1 Goal: make as MANY airplanes as you can. 5 minutes! Goal: make as MANY airplanes as you can. Manufacturing Engineering Team – all members must have unique roles and must repeat their step for each plane. As soon as you finish your step pass it to the next person as quickly as possible; if they are working on another one that’s okay, set it on their workstation and keep going with your step! When the plane is complete the last production engineer will give it to the quality engineer. Quality Engineer Will visually inspects each plane against the Golden Image: pass/fail When the Clock has Stopped: Quality Engineer will test passing planes and calculate team metrics. Each plane sells for $20.00 and the WIP cost is $5.00/plane Winning Team: The most quality planes at the end of the round Have fun!

Time to do a flight test! Move to your team’s test area Test only the planes that pass visual inspection Keep track of the # of planes that pass the 5 ft. flight test. These are “good” planes. Complete your team’s metric sheet

Round 1: Metrics Metric Metric Definition Round #1 Round #2 # Good # Planes built correctly (Flyable and pass visible inspection) % Good # good planes / total planes built Average Lead Time time it took to build good planes / total good planes built WIP # unfinished planes Productivity # good planes / # Engineers / 5 minutes WIP cost # of unfinished planes x WIP cost Profit (# Flyable planes x Sales price) – total WIP cost

What did we observe in Round #1? Were there any problems? Did any planes build up at a certain location? (bottleneck) Were there any quality issues? How would you make the next round better?

What is LEAN? Steps to drive process efficiency by eliminating waste Defects Overproduction Waiting Unused Talent Transporting Excess Inventory Excess Motion Extra Processing

Lean Method-Round 2 For this round, your goal is to maximize profit without sacrificing the quality of the planes. Excess WIP is a problem – we don’t want any. Engineering Team – take two minutes to reconfigure your teams to support your “LEAN” process. There will now be a staging area to prevent overproduction. Each person on each team will get a post-it. You will only be allowed to produce your part of the plane when your post-it note is not covered by WIP. Quality Engineer will enforce these rules. Once time is up… Quality Engineer will inspect your planes and calculate your metrics. Sales price for each plane is $20.00 WIP cost per unit is $5.00. 5 minutes!

Time to do a flight test! Go back to your test area “Good Planes” = those that can fly > 5 feet.

Round 2: Metrics Metric Metric Definition Round #1 Round #2 Good # Planes built correctly (Flyable and pass visible inspection) % Good #good planes / total planes built Average Lead Time time it took to build good planes / total good planes built WIP # unfinished planes Productivity # good planes / # Engineers / 5 minutes WIP cost # of unfinished planes x WIP cost Profit (# Flyable planes x Sales price) – total WIP cost

Round 2: Follow-up Which production method would you choose for your company? Why? Which team made the most profit? How did the changes we made with resource-leveling and WIP change our metrics results? How did our quality improve? Did you see any areas where STEM was involved?

Activity Summary We learned about Supply Chain using Paper Airplanes! Source Make Deliver Reuse/Recycle We learned about Science, Technology, Engineering & Math too! Science: Optimize your paper airplane flight distance Technology: Mass Production of Automobiles Engineering: Improving the production of paper airplanes (LEAN) Math: Calculating Metrics What else did you learn today that was new? Did you have FUN?

Please… RECYCLE ALL PAPER PLANES AFTER ROUNDS ARE FINISHED (can bring to younger students, or recycle)

Round 1 Discussion Aide: Page 24 Positive: Cost per unit goes down as profit goes up Negative: Overproduction and excess WIP is costly and wasteful. Items to consider for additional discussion Compare winners based on profit Who would the winner be if each WIP cost $5? What would happen if the customer suddenly demanded a change or a different product? What if October demand dropped to 3 planes? Who would be the winner each plane that had to be scrapped cost $5? Does the overproduction seem wasteful if we don’t need it? Is making the most airplanes the correct incentive for workers? How can we better control WIP? How does this type of process impact quality?

Power Point Display + Whiteboard Area Classroom Set Up Front Of Class/ Power Point Display + Whiteboard Area 5 ft. 5 ft. Team #2 Test Flight Wall Team #1 Test Flight Wall Team #1 Table Team #2 Table 5 ft. Team #3 Table Team #4 Table Team #4 Test Flight Wall Team #3 Test Flight Wall 5 ft.

Activity Kits/Supplies List of materials Needed for 1 team of up to 7 students ~75 sheets of paper* 1 pad of post it notes (any size) 1 calculator (or smart phone with calculator) 1-2 pencils 1 set of 50 small lightweight stickers (stars, other) 1 metric sheet – slide 36 *Use standard copier paper (lightweight) to aid in ease of folding a flight. *Nice to have a unique color paper for each time, but not required. List of materials Needed for 1 class of 28 students (4 teams of up to 7 students) ~300 sheets of paper* (or 1 ream) 4 pads of post it notes (any size) 4 calculators (or smart phones with calculator) 5-10 pencils Ability to display a power point in the class Chalkboard & Chalk, dry erase board & markers, or flip chart + marker 4 sets of 50 small lightweight stickers (stars, other) each set a unique color 6 metric sheet print outs – slide 36 (includes 2 spares for mistakes)

Team Name____________________________________ Metric Metric Definition Round #1 Round #2 # Good # Planes built correctly (Flyable and pass visible inspection) % Good # good planes / total planes built Average Lead Time time it took to build good planes / total good planes built WIP # unfinished planes Productivity # good planes / # Engineers / 5 minutes WIP cost # of unfinished planes x WIP cost Profit (# Flyable planes x Sales price) – total WIP cost