Cairo University Mechanical Design and Production Dep.

Faculty of Engineering

MDP408B – Operation management – Spring 2021

Lab # 1 – Theory of constrains, “Goldratt's Dice Game”.
May. 2021

Student Name: ID:

Objective:
To help:
• Introduce the meaning of bottlenecks [Identify the system constraints (bottleneck)].
• Identify the impact of changing conditions on the bottleneck thus the system overall.

Lab Idea:
Apply one of TOC Games - Goldratt's Dice Game
https://www.youtube.com/watch?v=IsNslFftjcA
The Goldratt's Dice Game is a workstations simulation based on moving parts through workstations, it is
ideal for demonstrating the following concepts:
- bottlenecks
- balancing capacity
- alternating the constrains

This is normally run over 3 rounds of 20 delivery cycles with discussion on learning and improvements
made between each round.

Setting:
a workshop consists of 6 baskets each basket representing a workstation, number of products (ex: torches) and,
a dice to roll with each student to identify the number of products that each basket (workstation) will have.
And a penny to be used in round three to determine the capacity for each workstation.
The instructor will give the students needed instructions at the beginning of each round.

Procedures:
1. Each player rolls the dice to determine how many products to place in his basket at the beginning of the
run only. This represents one day's production for that operation. For example, if the first player rolls a
six, then he places six products in his basket. If the next player rolls a four, he can only move four products
from the first basket to his basket. Start to produce by the predetermined values, the production continues
for the run time (20 cycles) then record total net production.
2. Round Two, same as round one, but putting WIP inventory of 4 between workstations at the beginning of
the run.
3. Round Three, same as round one, however the method of determining the capacity at the beginning not by
rolling the dice but with tossing a penny as the head will represent the bottleneck capacity and tails
represents higher than the bottleneck capacity with (one).

Page 1 of 3
 Cairo University Mechanical Design and Production Dep.
Faculty of Engineering

Observations / Data Collection:

1- Identify the basket of the lowest product quantity and note this value (this represents the workstations
bottleneck).
2- Record the net production done in the 20 cycles for each run.
3-Record the WIP after the 20 cycles for each run.

Data Collection Table Sample:

Cycle Net WIP

number production
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Page 2 of 3
 Cairo University Mechanical Design and Production Dep.
Faculty of Engineering

Assignment (Points for discussion):

1. Identify the bottleneck workstation and give a comment on its effect on the production line.
2. See the effect of each run changed conditions on the net production.

Improvements Proposals:
Give suggestions of other procedures that can optimize the operation (on the basis of TOC procedures).

Evaluation and Recommendations:

Do you think that this lab was helpful?
Totally Agree Agree May be Not Agree Totally not Agree

How can this lab be improved?

Page 3 of 3
 Cairo University Mechanical Design and Production Dep.
Faculty of Engineering

MDP408B – Operation management – Spring 2021

Lab # 2 – Theory of constrains, “Nickel Game”.
May. 2021

Student Name: ID:

Objective:
To help:
• Demonstrating the difference between local efficiency (machine capacity) and global efficiency
(through-output rate).
• Identify the impact of eliminating constrains (idle time).

AN HOUR SAVED AT THE BOTTLENECK ADDS AN EXTRA HOUR

TO THE ENTIRE PRODUCTION SYSTEM.

Lab Idea:
Apply one of TOC Games - Nickel Game
https://youtu.be/zlgO5_RNX_Y
The Nickel Game is a workstations simulation based on moving coins through workstations, it is ideal for
demonstrating the following concepts:

- local efficiency and global efficiency

- eliminating the constrains

This is normally run over 2 rounds each round takes average 3 minutes to complete by 7 participants
representing the workstations with discussion on learning and improvements made between each round.

Setting:
a workshop consists of 7 participants standing on table all in-line each participant representing a workstation,
products are ten large coins placed on the table all faced heads or all faced tails, and stop watch at each
workstation to take time period in each phase.
The instructor will give the students needed instructions at the beginning of each round.

Procedures:
1. First round: Each person turns the coins from all coins from “All Heads up” to “All Tails up,” then slides
the coins to the next person. A person calls out the time at the end of the round. Each player records the
time with their stop watch when they pass the batch of coins. After everyone is finished, subtract the
previous player’s completion time from your completion time to determine how long it took you to turn
the coins.
2. Second round: A new policy is put into place that requires everyone to put one hand behind their back and
turn coins with only one hand. To make up for the slowness, each coin may be passed immediately to the
next person in line who can begin as soon as they have a coin. Play again until everyone has flipped all
ten coins.

Page 1 of 3
 Cairo University Mechanical Design and Production Dep.
Faculty of Engineering

Observations / Data Collection:

1-In the first round, after all have had a chance to turn the coins, take and record the completion time from each
workstation. Everyone will have a completion time between 5 seconds and 10 seconds (finishing about
7*number of players; with 7 players, it takes about 49 seconds).
2-In the second round, it is harder to be accurate on how much time it takes for each person to flip the coins one
at a time. They all start within just a few seconds and all end within a few seconds of each other. But, you can
get the idea. It takes from 10 to 20 seconds per person to flip the ten coins; twice as long. However, the time
to complete all ten coins is about 4*number of players (for 7 players its about 28 seconds).
3-Or for accurate data collection use the coming table.

Data Collection Table Sample:

Round station Cumulative time Station time (sec)

(sec)
One 1

Two 1

Page 2 of 3
 Cairo University Mechanical Design and Production Dep.
Faculty of Engineering

Assignment (Points for discussion):

1. State the difference between local efficiency and global efficiency as in previous runs number and as
definitions.
2. Give the reasons behind second run better global efficiency comparing to the first run.

Improvements Proposals:
Give suggestions of other procedures that can optimize the operation (on the basis of TOC procedures).

Evaluation and Recommendations:

Do you think that this lab was helpful?
Totally Agree Agree May be Not Agree Totally not Agree

How can this lab be improved?

Page 3 of 3
 Cairo University Mechanical Design and Production Dep.
Faculty of Engineering

MDP408B – Operation management – Spring 2021

Lab # 3 – Theory of constrains, “Dollar Game”.
May. 2021

Student Name: ID:

Objective:
To help:
• Demonstrating typical problems with misunderstanding and poor communications with planning in
large organizations.
• Demonstrating the impact of rope existence between workstations and between market and
production facility.

Lab Idea:
Apply one of TOC Games - Dollar Game
https://youtu.be/u4ygeUg40-w
The Dollar Game is a workstations simulation based on moving coins through workstations, it is ideal for
demonstrating the following concepts:

- Blind production
- Ropes communication

This is normally run over 1 round takes average 5 minutes to complete by 7 participants representing the
workstations with discussion on learning and improvements made between each round.

Setting:
a workshop consists of 7 participants standing on table all in-line each participant representing a workstation,
products are big pile of random coins placed in basket, and stop watch to take time period representing a week.
The instructor will give the students needed instructions at the beginning of each round.

Procedures:
1. Each player places one hand behind their back. The first player draws coins at random from the cup of
mixed coins and passes the coin to the next person. Each person in turn turns the coin over and slides them
to the next person who flips coins one at a time passing them to the next player immediately.
2. everyone freezes every ten seconds (representing a week).
3. Scoring: At the end of each week (10 seconds, 20 seconds, 30 seconds, …) a person acting as the customer
examines the Finished Goods coins. The coins are arranged by denomination.
4. If there are four coins of the same denomination, they form a completed project and the customer
announces, “Oh a finished project. Great, this one is worth <blank> amount.”
5. The amount for the project is determined by the denomination (4 quarters=$1,000, 4 halves=$5,000,
4 pounds=$10,000. Use of foreign coins can provide a $1 million).

Page 1 of 4
 Cairo University Mechanical Design and Production Dep.
Faculty of Engineering

6. After 30 seconds, it’s time to slowly and somewhat quietly get the last person in the line to understand
clearly that it takes four coins of the same denomination to complete the project and the value varies
depending upon the denomination. As soon as (and whenever) this clarity is given, play continues.
7. Before the last minute of the 5 minutes run we stop the game and make a rope between the last player and
the first one, at this moment the last player tells the first one the idea of that every four similar coins
represent a completed project/product and that what makes money for the firm/workshop.
8. The last minute of run starts with that information given for the player and we will see effect of the rope
mechanism.

Observations / Data Collection:

1-The first person in the line was pulling coins as fast as possible but at random without regard to what was
needed.
2-Individuals in the middle of the line were so busy flipping coins, they didn’t pay much attention to anything
else.
3-The last person in the line is connected to the customer but did little to tell anyone else about the “Four Coin”
projects, so lake of communication still present.
4- In the last minute the rope communication effect will take place eliminating the lake of communication
between the different levels of work environment.
5- the players have to record each week selling value through coming procedure.

Calculations procedures:
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑞𝑢𝑎𝑟𝑡𝑒𝑟𝑠 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐻𝑎𝑙𝑣𝑒𝑠 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑃𝑜𝑢𝑛𝑑𝑠
∗ (1000) + ∗ (5000) + ∗ (10000)
4 4 4
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑓𝑜𝑟𝑔𝑖𝑒𝑛 𝑐𝑜𝑖𝑛𝑠
+ ∗ (1 ∗ 106 ) = 𝑊𝑒𝑒𝑘 ′ 𝑠 𝑡𝑜𝑡𝑎𝑙 𝑠𝑒𝑙𝑙𝑖𝑛𝑔 𝑣𝑎𝑙𝑢𝑒
4

Assignment (Points for discussion):

1. Define what is rope, what its benefits and how these benefits reflect on overall through output.
2. Give suggestions of how to Prioritize work for Workers on the Line.
3. compare your results before and after applying the rope.

Page 2 of 4
 Cairo University Mechanical Design and Production Dep.
Faculty of Engineering

Data Collection Table Sample:

Quarter Halve Pound Foreign Total

value $1,000 $5,000 $10,000 $1 milli
Week 1
Week 2
Week 3
Week 4
Week 5
Week 6
Week 7
Week 8
Week 9
Week 10
Week 11
Week 12
Week 13
Week 14
Week 15
Week 16
Week 17
Week 18
Week 19
Week 20
Week 21
Week 22
Week 23
Week 24
Week 25
Week 26
Week 27
Week 28
Week 29
Week 30

Page 3 of 4
 Cairo University Mechanical Design and Production Dep.
Faculty of Engineering

Improvements Proposals:
Give suggestions of other procedures that can optimize the operation (on the basis of TOC procedures).

Evaluation and Recommendations:

Do you think that this lab was helpful?
Totally Agree Agree May be Not Agree Totally not Agree

How can this lab be improved?

Page 4 of 4