Gazelle’s Leanworks

Materials
and
Instructor Notes

© 2023 Gazelles. All rights reserved 1

Game Inventory Requirements

12 Lego Cars to be Assembled

Part List
1. Chassis – 12 Nos
2. 4 Tyres – 48 Nos
3. 4 Tyre Rim – 48 Nos
4. 1 Seat – 12 Nos
5. 1 Wind Shield – 12 nos
6. 1 Gear Lever – 12 Nos
7. 1 Seat Cover – 12 Nos
8. 1 Steering Wheel – 12 Nos
9. 1 Bonet – 12 Nos
Part List Images
 Participants Requirement

 Station 1: Chassis and Seat

 Station 2: Tyre Assembly (Rim +Tyres)

 Station 3: Wheel Assembly, Steering and seat cover

 Station 4: Wind Screen, Gear and Bonet

Station 5: Quality inspection

 Station 6: Customer
 Material Handler
QA Car Samples
QA Car Samples
 Supplier
Workstation
Workstation #1
Workstation #2
Workstation #3
Workstation #4
Workstation #5
QA
 Customer
Workstation
LEGO AUTO Swift Corp. Measures
Round Round Round
1 2 3
•Lead Time (per unit)

•Work in Process (units)

•Space required (tables)

•Workers (headcount)

•Defectives (internal & external units)

•Productivity (units/person)

•Output (good units delivered)

LEGO AUTO Corp. Financials
Round Round Round
1 2 3
•P&L Statement
• Inventory Carrying ($0.5k/unit)

• Space Costs ($10k/table)

• Labor ($5k/worker)

• Defectives (Internal= $2k; External=$5k)

•Total Costs
•Sales ($2k /good unit delivered)

•Profit / Loss
 Gazelle’s Leanworks Roles - Supplier

• Workstation supplier
• The supplier is responsible for supplying material to
each workstations
• When in box of station one is empty, refill
• The refill is 3 car equivalent parts.
• You are allowed to only place a total of 3 car sets in the
in-box.
 Gazelle’s Leanworks Roles - Workstation #1

• Workstation 1:
• 1. Retrieve parts from In Tray.
• 2. Take Chassis and seat from the in-tray and assemble as
per specification. Place the assembled set in out-tray
• 3. Complete this exercise for all 3 cars by picking from in
tray one at a time and placing in out tray
• 4. Raise your hand to signal the material handler for delivery
to the next workstation
• 5. Continue with the next “batch.”
• 6. Work as fast as you can.
 Gazelle’s Leanworks Roles - Workstation #2

• Workstation 2:
• 1. Retrieve Rim and tyre from In Tray.
• 2. Take Rim and tyre from the in-tray and assemble the
same. Post assembly, place in out tray.
• 3. Complete the three cars and place in Out Tray one by one
• 4. Raise your hand to signal the material handler for
delivery to the next workstation
• 5. Continue with the next “batch” if available.
• 6. Work as fast as you can.
 Gazelle’s Leanworks Roles - Workstation #3

• Workstation 3:
• 1. Retrieve Wheel assembly, steering wheel and Seat cover
from In Tray.
• 2. Take Wheel assembly, steering wheel and Seat cover and
assemble them one at a time.
• 3. Complete the assemble to form 3 sets and place in Out Tray
• 4. Raise your hand to signal the material handler for delivery
to the next workstation
• 5. Continue with the next “batch” if available.
• 6. Work as fast as you can.
 Gazelle’s Leanworks Roles - Workstation #4

• Workstation 3:
• 1. Retrieve wind Shield, Bonet and gear from In Tray.
• 2. Assemble the three parts on the car
• 3. Complete 3 cars to form a set and place one at a
time in Out Tray
• 4. Raise your hand to signal the material handler for
delivery to the next workstation
• 5. Continue with the next “batch.”
• 6. Work as fast as you can.
Gazelle’s Leanworks Roles - Workstation #5

• Workstation 4:
• 1. Retrieve forms from In Tray.
• 2. Quality check the work of all the previous
workstations,
• Ensure each form has been completed in accordance with the
instructions given to each of the workstations.
• Place any defective materials in a separate stack.
• No rework is allowed
• 3. Sign your name on the designated line. Complete
Three forms in the set and place in Out Tray
• 4. Raise your hand to signal the material handler for
delivery to the customer
• 5. Continue with the next “batch.
• 6. Work as fast as you can.
Gazelle’s Leanworks Roles - Customer

• Your Stopwatch will start and end each simulation:

• Start your watch when the first workstation begins work.
• Stop your watch when the facilitator stops the activity.
• Quality check the work of all the previous
workstations, ensuring that each form has been
completed in accordance with the instructions
given to each of the workstations.
• You must receive batches of 3 cars in Round 1.
• Place any defective materials in a separate stack.
• No rework allowed.
• Demand is One stack per 30 Mins, after 3 minutes
of loading time.
 Gazelle’s Leanworks Roles - Material Handler

• Material Handler
• When someone raises their hand:
• Transfer their work to the next workstation.
• Ensure the work is transferred in batches of Three.
• Ensure that work is moved in a FIFO process (First in, First Out).
Gazelle’s Leanworks Roles– Lead Time Timer

• Timer 1:
• Start your watch when the first car
starts getting picked in assembly and
get dropped in last outbox post finished
• Measure lead time for atleast 6 cars in
given scenario

• Lead Time measures per round

Gazelle’s Leanworks Roles– Process Timers

• Process Timers:
• Your job is to understand the amount of
time it takes to do each workstation’s
work content
• Start your watch when the worker begins
the task
• Stop your watch when the worker ends
the task of 3 cars
• Record the observed times in seconds
• Divide the answer by three to get the average
time per car
• Get 5 observations per workstation
• Capture the highest and lowest times and
average
 Gazelle’s Leanworks Roles – Spaghetti person

• Spaghetti person.
• Draw a physical layout of the simulation, on a flip chart.
• Your task is to follow and draw the path of the material
handler.
TIPs:
• Pretend a GPS tracking system is strapped to the Material Handler and
you are tracing the route on the physical layout map.
• Show all movement of the Material Handler regardless of whether
he/she is carrying product.
 Gazelle’s Leanworks Roles– Process Map person

• Process map person

• On a flip chart make a SIPOC of the process and a
Macro view of the flow of the Process.
 Gazelle’s Leanworks Roles - Observers

• Observers:
• Observe the process:
• Note pros and cons of the process
• Identify the level of management visibility of the process
• Determine the level of utilization for each of the workstation
• Determine how the world class principles could be applied, save these thoughts
for the next round.
• Information gathered will be used to make an As-Is Value Stream
Map
Round 1 Layout (separate space from classroom)

Simulation space (400 sq foot)

Supplier

Workstation #1 Workstation #3

Supplier

Workstation #2
Customer

Workstation #4 Workstation #5

Customer
Gazelle’s Leanworks – Round 2
Round 2 Layout – Instructor Notes
• Allow teams to make their own layout with an
explanation of why.
• The new standard is one every 30 seconds, with no
defects. Use it as an opportunity to teach Takt time.
Demand is 12 cars in 6 minutes of run time. Thus Takt
time calculates to 30 seconds.
Round 3 Layout – Instructor Notes
• Allow teams to make their own layout with an
explanation of why.
• The new standard is one every 15 seconds, with no
defects. Use it as an opportunity to teach Takt time.
Demand is 12 cars in 3 minutes of run time. Thus Takt
time calculates to 15 seconds.
 Intellectual Property Clauses

• This proposal is strictly confidential.

• This proposal contains confidential material proprietary to Gazelles Management Consultancy
(Gazelles). The materials, ideas, and concepts contained herein are to be used exclusively to
evaluate the capabilities of Gazelles to assist T3 Aviation Academy,Sharjah.
• The information and the ideas herein may not be disclosed to anyone outside T3 Aviation
Academy,Sharjah or be used for any purpose other than the evaluation of Gazelles
capabilities.
• Should you decide not to engage Gazelles, please return this proposal along with any
photocopies, and ensure that this document is not distributed to, or shared with, other parties.
• This proposal is made by Gazelles, and is in all respects, subject to negotiation, agreement
and signing of specific contracts.
© 2023 Gazelles. All rights reserved 35
 Outline

Background
Why Gazelles
Lean Six Sigma White Belt workshop
Payment Terms & Conditions
Gazelles Profile
Curriculum Vitae of Key Personnel
Our Clients & Workshop

© 2021 Gazelles. All rights reserved 36

 Background

© 2023 Gazelles. All rights reserved 37

 Background
T3 Aviation Academy, Sharjah was incepted in 2008, a pioneer in aviation training
programmes and services which are in line with the industry’s highest standards.

As a part of strategic objective and continuing commitment to excellence , T3 Aviation

Academy,Sharjah intends to build a sustained culture of excellence by introducing Lean Six
Sigma methodology in the Organization.

Consequently, T3 Aviation Academy,Sharjah requires the assistance of Gazelles to

provide support as a value added partner during the training program of Lean Six Sigma
White Belt Program.

©
© 2023
2021 Gazelles.
Gazelles. All
All rights
rights reserved
reserved 38
 Our Proposed Work Approach

© 2023 Gazelles. All rights reserved 39

 Overall Program Sequence

Program Sequence Duration

Lean Six Sigma White Belt workshop 5 days

Number of Participants per batch-max. 14

© 2023 Gazelles. All rights reserved 40

 Course Content (1 Day) Lean Six Sigma White Belt
Module-1 Module-2
Lean Overview and Seven Waste Six Sigma Overview

A. Lean Challenge Framing A. What is Six Sigma

Exercise B. DMAIC Methodology
B. Lean Overview C. Project Charter
C. 5 Principles of Lean D. Process Mapping
D. Value Stream Group Exercise E. Fishbone
E. Concept of Value & 8 Wastes F. Graphical Analysis
Lean Principles G. Solution Generation
F. Implementation Approach H. Control Mechanism
G. ECRS

© 2023 Gazelles. All rights reserved 41

 Adult Learning Process
Stages of Learning New Traits

BMGI’s programs are designed to build Core Competency as shown below:

Conscious
Consciously Consciously
Incompetent Competent
S.O.P.

Practice
Awareness
Degree of Consciousness

Sub-conscious

Subconsciously
Subconsciously
Competent
Incompetent
(core competency)

Incompetent Competent
Degree of Competency
© 2023 Gazelles. All rights reserved
 Whole Brain Thinking Approach
The importance of the four lobes in training is that knowledge is not yours until it has
moved into long-term memory. This is done through using as many of the lobes as
possible and repetition. The more the entry points into memory, the better recall the
learner will have. Gazelles uses this fundamental in training as shown below:

Memory
Motor
Trainer Includes the following in the sessions:
Allow the learners to:
• Repetition & revision
• Talk
• Creating links to existing knowledge Motor • Participate in an activities like
• Games and puzzles
puzzles, quizzes and games
• Answer questions
Memory • Ask questions
• Work in teams
• Participate in role plays

Vision
Hearing
Allow the learners to:
• Listen Vision
• Ask questions Allow the learners to look by using:
• Answer questions
Hearing • PowerPoint & Flipchart
• Listen to stories • Videos, pictures & graphics
• Listen to anecdotes • Reading material (in learner manual,
• Listen to music or use rhythm and rhyme articles, books etc)

© 2023 Gazelles. All rights reserved

 Training / Workshop Methodology

Customized Learning
based on the reinforcement
Industry & through LEGO®
sector specific SERIOUS
challenges PLAY® Method

Real time case

Quizzes &
studies and
Questionnaire
scenarios

Special note :
Content shall be designed & delivered in English
© 2023 Gazelles. All rights reserved 44
 Program Deliverables
After the completion of training, participants' will have clear understanding of the
following concepts :
• Gives the participants a comprehensive knowledge of Lean Six Sigma Methodology
• Enables participants to understand the role of a Lean Six Sigma as a key change agent in their organizations
• Enables participants to understand linkage between business priorities and practices of Lean Six Sigma
management
• Participants would understand the importance of data analysis for effective decision making.
• Get to know deployment strategy
• How to select Lean projects
• How to implement Lean project using Kaizen methodology
• How to launch Lean Six Sigma initiative in the organization
• Participants shall pick up at least one Kaizen Project to finish post completion of workshop
• Participants shall be creating a Kaizen event Project bank to be implemented post completion of the workshop.
© 2023 Gazelles. All rights reserved 45
 Assumptions
We have made the following assumptions with respect to this program and would
like to confirm or clarify these before the commencement of the program.

• There will be complete executive sponsorship and support within T3 Aviation

Academy,Sharjah on the successful delivery of the program.
• Training Shall be conducted on the premise of T3 Aviation Academy,Sharjah.

• There shall be a single point of contact provided by T3 Aviation Academy,Sharjah for

training coordination.
• All the relevant T3 Aviation Academy,Sharjah staff will be readily available and fully
involved as required throughout this engagement.
• In the event you propose a change in the scope of work mentioned in this proposal, the
revised scope and our professional fee shall be mutually discussed and agreed with you.
© 2023 Gazelles. All rights reserved 46
 Commercials

© 2023 Gazelles. All rights reserved 47

 Estimated Days and Fees
Our professional fees are based on the time required to carry out the work, evaluated at rates appropriate to
the experience of the personnel assigned. Our rates are set at levels, which enable us to provide first class
service.

• 100% Payment of training fee in advance before the commencement of the Program.
These fees have been derived based on our estimated involvement across the levels of professional personnel
required, as follows:

Total Total Number Per day fee Total Amount exclusive 5%

Activity of People per
Duration (AED) VAT(AED)
batch
AED 22,000
Lean Six Sigma 4 days Max. 14 5500 ( Twenty-two thousand dirhams
White Belt Workshop only)

Complimentary Lean Max. 14

Six Sigma White Belt 1 day 0 0
Workshop

• The estimated fees exclude 5 % VAT .

© 2023 Gazelles. All rights reserved 48

 Curriculum Vitae of Key Personnel

© 2023 Gazelles. All rights reserved 49

 Our People . . .

• At Gazelles, we believe people are the key to building effective partnerships. The team have
selected to serve you, consists of the right people, with the right skills to meet your specific
business needs and culture - people with the relevant industry experience, commitment,
knowledge and personality to work with you in a proactive and positive way.

• Our Gazelles team will deliver strong industry knowledge, commerciality, vision, thought
leadership and depth.

• It is a team that will challenge, when necessary, bring issues to the table as soon as they
arise, and act as an independent sounding board for management.

© 2023 Gazelles. All rights reserved 50

 Name: Sweta Pandey (Lean Six Sigma Master Black Belt, Design Thinker, DASM)
Position: Trainer Innovation & Lean Six Sigma , Disciplined Agile, Lego simulation
Years of experience: 17 years
Field of Specialization : Innovation, Business Excellence, Lean Six Sigma, DFSS, Disciplined Agile ,Design Sprint
and LEGO© SERIOUS PLAY® Facilitator.

Sweta Pandey is a Certified Lean Six Sigma Master Black Belt and DQA,DHDA, Taqdeer and Innovation Awards Assessor with over 17 years of experience in
innovation, business excellence, process excellence. She is an expert in designing industry specific lego simulation based on LEGO© SERIOUS PLAY® for
conceptual learning.

She brings in extensive experience in managing the entire Change Management, Competency Assessment, linking strategy with operations through
Coaching and Mentoring functions.

She holds a Management degree in Human Resource and a certified Lean Six Sigma Master Black Belt professional.

She is also a certified SAP-HR Functional Consultant from SAP Germany and certified ISO Lead Auditor 9001:2015.

She has also been awarded as Business mentor of the year 2022 for her contribution in SME growth.

She has rolled out multiple innovative product in her career such as Lean Project Management in Education, ISO 18404:2015 consulting and certification,
Design sprint certification program.

Sweta is exceptionally proficient with overall 17 years of experience in optimizing teams dynamics, uniting diverse agendas to a common goal, and
harnessing strategic and operational drivers to deliver results. She has helped various clients in manufacturing service and retail industry to improve their
operational efficiency by improving process and people with a cost saving of more than $88 million.

Clientele:- MOH, DHA, Al Naboodah, Aggreko Middle East, Sobha Façade, Sobha reality, Eternity Technologies, Lulu Exchange, Al Fajer facility management,
MAHY Khoory, Daman Group(Kuwait), H.E.M.T, Healthpoint ,Ducast, KHK Scaffholding, NMDC, NPCC, Berkeley Services, Riyadh airport, SABIC.

© 2023 Gazelles. All rights reserved 51

 Name: Roswin Teles (Lean Six Sigma Master Black Belt, TPM)
Position: Director- Operation Excellence
Years of experience: 22 years
Field of Specialization: Digital Transformation, Business Analytics ,Bachelor of Engineering( Mechanical)

As an Operational excellence expert and Lean Six Sigma Master Black Belt, Roswin Teles has been helping clients develop strategy and transformations, in-source
creativity and drive organizational growth for more than a decade.

Roswin’s counsel is invaluable during all phases of any transformation initiative, and he has become a trusted advisor/ mentor/coach for employees across all
levels in a variety of industries. Roswin is a motivational speaker and thought leader in developing innovative concepts for delivering breakthrough results.

Achievement:
• Advised and supported 50+ large and medium size organizations in India delivering EBIDTA impact of over USD 20 Million and new business opportunities of
over USD 2.5 Billion.
• Felicitated by the CEO as “Employee of the Year” for successfully leading team of 55 members and enhancing the capacity of tractor assembly line from 90 to
120 tractors/day with minimal investments and delivering savings of 1.8mn Euros.
• Designed and Commissioned Lean engine and transmission assembly lines for Daimler Trucks India through collaboration with experts from Fuso Japan and
Daimler Germany.
• Increased productivity of cages in bearings by 40% leading to elimination of 1 shift within 3 months at global largest tier 1 supplier to ball bearing
companies(Harsha Engineers)
• Remodeled entire composition to deliver defect free and low cost asbestos roofing sheets through application of DOE on a 30K Tonnes per year capacity
equipment
• Designed and developed machines to convert manual processes into fully automatic production lines leading to doubling of output and no human
interventions in an oil seal company
• Passionate about training and mentoring people. Developed over 2000 Change Agents across 40 organizations and support over 800 projects spanned over
several industries.
Clientele:- Accenture, BMGI, DR. Reddy’s, Daimler, TCS, Accenture,E bayAl Naboodah, Aggreko Middle East, Sobha Façade, Eternity Technologies, Lulu Exchange,
MAHY Khoory, Dhaman Group(Kuwait), H.E.M.T, Healthpoint, NMDC, NPCC, ITC.

© 2023 Gazelles. All rights reserved 52

 Name: Naresh Chawla (Lean Six Sigma Master Black Belt, TPM, Business Analytics)
Position: Senior Trainer Innovation & Lean Six sigma and Operational Excellence
Years of experience: 27+ years
Field of Specialization: Innovation, Business Excellence, Lean Six Sigma, DFSS

Naresh Chawla is a Certified Lean Six sigma Master black belt , ZED Certified Trainer with over 24 years of experience in innovation, business excellence, process
excellence.

He has trained close to 4000 resources on TQM, Lean and Six Sigma in Healthcare, retail, construction, Services, manufacturing , BPOs , BFSI, KPOs across the
globe in innovation, Six Sigma, Lean, Supply Chain, BPMS, Project / process Management & Quality management.

He has worked for National Productivity Council as Deputy Director for almost 13 years. Transformed more than 30 MSME units using lean practices such as 5S,
VSM, Kanban, Quick Change over, Mistake proofing, Kaizen. Cumulative recurring savings in these units were around $21mn per annum. His Case study of
transformation of an industry got recognition in APO News (Mar-April 2014), Japan.
Hands on experience of leading sponsored from central and state ministries.

His Core competency in blending practical experience and integration of lean six sigma approach , tools and techniques for achieving sustainable organizational
transformation in manufacturing, transactional and service sectors.

He has been a guest faculty at premier institutes such as IIM Kashipur, IIT, Roorkee, Balaji Society, Pune, IIMHR, Jaipur.
He has also been awarded CERTIFIED QUALITIST Level 3 Badge by QIMPRO, Mumbai, a unique mark of excellence among Quality & business excellence
Professionals, for my contribution to the field of Quality Management in 2019

Clientele:-Ministry of Health, Vardhman Industries, Al naboodah, Tata Steel, kddl Ltd., Dr. Reddy’s, Al Fazer Facility Management, Kokilaben Dhirubhai Ambani
Hospital Mumbai, Kasturba Hospital, Manipal, Lokmanaya Hospital Pune, Johnson & Johnson.

© 2023 Gazelles. All rights reserved 53

 Gazelles Profile

© 2023 Gazelles. All rights reserved 54

 About Gazelles
Gazelles Management Consulting is a global consulting firm helping organizations to transform their business performances.

Gazelles Facts & Figures

• Founded in 2013 by leading Change & Continuous
Improvement experts
Savings in excess of
USD 20 Billion • Headquarters in Dubai, United Arab Emirates with global
clients

• 100+ successful deployments worldwide

• 90% of Business through referrals

• ROI ranges from 5:1 to 20:1

UAE OMAN INDIA SAUDI SOUTH Kuwait

AFRICA Bahrain UK
ARABIA

80+ Active Customers Corporates Family-owned Business Educational Institutes Government

© 2023 Gazelles. All rights reserved

 Gazelles Toolkit for Business Transformation

© 2023 Gazelles. All rights reserved

 Operational Excellence Impact and Benefits

Success is
Guaranteed!

© 2023 Gazelles. All rights reserved

 Our Clients & Workshop

© 2023 Gazelles. All rights reserved 58

Strategic Partners
 Partial list of clients Gazelles worked with..
Some of the clients Gazelles Coaches and Trainers worked with..
Some of the clients Gazelles Coaches and Trainers worked with..
 Gazelles Contribution & Accolades

Value added supplier award from An appreciation award from Dubai Quality
Ministry of Health(MOH) group(DQG) as a strategic partner in
promoting quality across Dubai

SKEA Assessor appreciation Dubai Human Resource Development Best

© 2023 Gazelles. All rights reserved award Assesor Award(DHDA)
62
 Random Clicks of Gazelles Seminar & Workshop

© 2023 Gazelles. All rights reserved 63

 Glimpse of Future Life Skill –Education 4.0 Event

64
© 2023 Gazelles. All rights reserved
 Lean Six Sigma training for Ministry of Health
for Senior Management

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65
 Thank you

© 2023 Gazelles. All rights reserved

66