1 Alphabet Grid Game How To 1 ©-LHA-PFA-V5-09-07.

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Alphabet Grid Game

How To

1 ©-LHA-PFA-V5-09-07


1. Hand out sheets – face down2. Give instructions;

• Do not turn over until instructed• Sheet contains alphabet A to Z• Objectives are to pick out all the letters in sequence

Run 1; Underscore each letter in sequence Time allotted 20 seconds Instruct delegates to turn over page and start timing Ask each delegate how far they got Write up scores on a flipchart

Run 2;• As above this time overscore each letter• Time allotted 20 seconds • Ask each delegate how far they got• Write up scores on a flipchart

Run 3 – Use Gridlines (ask delegates to join up dots to form a grid);

• As above this time circle each letter• Time allotted 20 seconds• Ask each delegate how far they got

Run 4;• As above this time put a X over each letter• Time allotted 15 seconds

Discuss Key Learning Points


Learning1. With experience performance gets better2. With some guidance and structure can

achieve a lot more by learning from ‘experience’

3. Using simple tools and techniques can be powerful e.g. gridlines


Batch V Flow Game


Why do we need a change in thinking ?

Our mental faculties organise things according to Functions and Departments

It seems common sense to perform like activities together, in batches, because this will be efficient.

We ensure everybody is kept busy and all equipment is kept running.

Batch v Flow Exercise


Batch FlowV

Activity to compare a 4 step process•Batch of 10•Batch of 5

•Single piece flow


Batch FlowVStep 1

Step 3

Step 2

Step 4

Batch of 10Each step must process all 10 sheets. Move sheet from person to person to represent process.

How long will it take to process all 10 sheets through all 4 stages?

Rules-One handed

One sheet at a timeSign each sheet


Step 1

Step 3

Step 2

Step 4

Batch of 5Process the first 5 sheets then move onto the remaining 5 sheets.

How long will it take to process all 10 sheets through all 4 stages?

Same rules

Batch FlowV


Step 1

Single piece flowEach step must process all 10 sheets. Move sheet from person to person to represent process.

How long will it take to process all 10 sheets through all 4 stages?Same rules

Step 2 Step 3 Step 4

Batch FlowV


Learning points

Same people! Same Process! A change to the batch size and layout typically 2/3 less time

Qualitybatch of 10, a rework of (10+10+10+1) then rework=62 steps

Delivery/Flexibility/CashflowTypically 1/3 of the original production time.

First Part ThroughSpeed of response, massive reduction in waiting time

Why doesn’t everybody do it? Waste!

Batch FlowV


Toyota Quote

Value Vs. Waste

“All we are doing is looking at the time line from the moment a customer gives us an order to the point when we collect the cash. And we are reducing that time line by removing the non-value-added waste.”

Toyota Production System

1 Alphabet Grid Game How To 1 ©-LHA-PFA-V5-09-07.

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