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Great South
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Arron Stewart and Dave Fellowes
Introducing Arron Stewart and Dave Fellowes
August 10, 2022
Great South
Great South Workshops
August 18, 2022
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Lean Simulation at Stylecraft Stairs

people around a table building with blue lego

Kudos to the team at Stylecraft Stairs who paused production earlier this week to free up everyone to participate in the Lean simulation of building airplanes with Lego bricks.

The Lean simulation started off in a bit of chaos that is typical of many business production environments: The simulation shop floor was a mess, materials were difficult to locate; instructions were unclear; WIP was piled up in some areas, whereas others were waiting for work. Not a single plane got finished in the first round.

The team went through a Plan-Do Check-Act growth cycle of several improvement rounds, led by Nick Brownsword, one of Productivity People’s most senior consultants. Throughout the morning, various Lean Improvements were introduced and after successfully implementing 5S and Teamwork, production started to improve. In the last round, the product and material flow was completely altered and batch production was abolished in favour of one piece flow, this resulted in an impressive production of 51 planes in just 6 minutes.

The team was fully engaged and inspired, and I have the fullest confidence that this team will be successful in implementing their learnings to improve the productivity at Stylecraft Stairways. I wish them all the best on their Continuous Improvement journey.

About the author: Dr. Liddy Bakker is the Director of Knowledge Management and founder of Productivity People