Instructions
Welcome to All-World Wheelchairs! I’m James Johnson and I was recently hired as a lean representative to make this sub-optimal factory a bit more…optimal! I just got here and everything is in shambles. Let’s get started and see what we need to do to make a profit and save the company from going under.
Here is the factory floor. Here you can view and access the nine workstations, the purchasing page, and the office. The process of making one chair follows this diagram:
Tubes ---> Saw ---> Drill ---> Bender \/
Welder ---> Grind ---> Paint \/
Nylon fabric ---> Fabric cut ---> Sewing ---> Assembly <--- Wheels and metal
The color of each workstation relates to its performance during the previous month. Green = meeting production without overtime. Yellow = meeting production with overtime. Red = not meeting production.
The Welding workstation is red, mouse over it to see important information about it. Clicking on the Welding workstation will open the Welding workstation screen.
This is the Welding workstation screen. Clicking on the clipboard near the left of the table will open a station report. The station report gives you feedback specific to the current station.
Clicking on the truck icon will open the Purchasing page. This can be done from any screen. This is the Purchasing page. It displays information about the previous month’s orders.
Clicking on the desk icon will open the office screen. This can be done from any screen. The office is where you can access monthly reports and purchase lean tools. Clicking on the papers will open the Monthly Report for the factory.
This is the Monthly Report for the factory. It displays the factory’s income, expenses, and problems. The demand is 200 chairs per month with no extra production or backorders allowed. Clicking on the purple tab will open the monthly Problem List.
This is the monthly Problem List. It displays problems for each machine and their direct causes. The list will be very beneficial when deciding which lean tools will be the most beneficial. Clicking outside the Monthly Report will return you to the office screen.
Clicking on the phone will open the Lean Tools menu. Our lean tools represent methods of eliminating waste, including waste caused by both overburden and uneven workloads. Let’s try to improve the welding workstation. On the problem list the Welding station was broken down. Equipment PM might be the right choice.
Click on Equipment PM to view options and details. The Lean Tool tab for Equipment PM gives a short description of what Equipment PM will do for each station it is purchased for. The Lean Tool tab displays how much money you are able to spend on lean tools each month. Multiple lean tools can be purchased from up to two different categories of lean tools each month. Clicking on a checkbox will select the lean tool it corresponds to. Clicking on the Buy button after making a selection will purchase it permanently.
Clicking on the Next Month button will run the factory for one month will all previously purchased lean tools, and open the Monthly Report screen. Lean tools are only available for the first six months of the year. After July, you won’t be able to implement more lean tools.
Now that you understand the interface, try finishing the first month by checking the Problems List and implementing Lean tools.
These are tutorial instructions. For an instructor's guide, click here
