Lean & Lego: Building the Millennium Falcon Redux
summary
Office engineers turn a 5,000‑piece set and a 300‑page manual into a finished Millennium Falcon by applying measurable lean practices: value stream maps, cumulative flow and burn‑up charts, control charts, WIP limits and swarming. They identify a bottleneck (finding tiny parts), introduce a visual queue, split roles into finders and assemblers, and reduce batch size so cycle time drops from days/weeks to hours. Lego’s packaging change to small, ordered bags validates the reduce batch size lesson.
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chapters (4)
- 0:00Start
- 2:53Recap on Star Wars (Spoiler alert)
- 11:54Cumulative flow charts
- 49:07batch size, queue depth and cycle time
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