Enhancing the Agility and Performances of a Project with Lean manufacturing Practices.
Cvetkovic, Nela ; Moraca, Slobodan ; Jovanovic, Milos 等
Enhancing the Agility and Performances of a Project with Lean manufacturing Practices.
1. Introduction
Term agility implies flexibility, proactivity [1] and reactivity
[2]. Concisely, agility can be interpreted as "ability to
proactively or reactively adapt to change" [2]. In this context,
agility has significant relevance for software development projects,
where high uncertainty and frequent change requirements are mostly
inevitable.
Most of the software products are specifically tailored with
intents to fulfil customers' requirements and needs as successfully
as possible. However, only few of the projects intending to deliver
these products are defined as successful at the end of its
implementation; the deliverables of low percentage of software
development projects are recognized as satisfactory by the customers or
to have generated additional value to the users [3]. Alongside the major
project constraints according to PMBOK [4]: scope, budget, schedule,
risk, quality and resources, the most significant factors enhancing the
complexity of managing IT projects are: continuous changes of underlying
technologies, complexity of projects disabling realistic schedule and
budget estimations, ineffective project management skills, lack of
clients' involvement and clear requirements [2].These challenges
could not be overpassed with so-called traditional project management
methodologies since those entail extensive planning, up-front analyses
and design [5], are seen as robust, bureaucratic and process- centric.
As a response to the abovementioned challenges, Agile methodologies
have been introduced to the software project management. Agile approach
has proved to be adequate and useful when it comes to the greatly
important preconditions for successful projects: ability to respond and
react to the changing needs of customers and to reduce delivery time
[3]. Agile methodologies place the emphasis on stronger communication
and creation of useful product, while strict frameworks of predefined
project phases and extensive documentation are of the secondary
importance [6]. Nevertheless, some Agile principles were inadequate for
certain project types that require higher level of flexibility. The
time- boxed processes [7], exhausting work scheduling, and
non-applicability on large-scale projects, represent the most important
possible demerits, causing the constant pressure on team to finish its
sprint work on time in any circumstances, push system and in some cases
wrong effort estimations and time waste. During the evolution of agile
project methodologies, Lean approach has gained significant attention,
especially caused by opinion that certain Lean manufacturing principles
could improve agility and leanness of a project and redeem for
abovementioned possible problems with the most popular Agile
methodologies.
Considering that the practice implementation of lean manufacturing
principles into the Agile development process is relatively new, the
available literature and case studies are still limited. The aim of this
study is to introduce the adjusted Lean principles, which were seen as
adequate for enhancing project agility (flexibility and adaptability),
to the Agile software development project and totestif these changes
consequently result in improved project team performances.
2. Theoretical background
2.1. Lean manufacturing principles in Agile project management
Lean thinking has its roots in Toyota (then called Toyota
Production System) where has been created in the mid-70s. The
publication of the book "The Machine that Changed the World"
[8] started the diffusion of lean manufacturing practices first of all
in automotive industry and later in all other industries from
agriculture to aerospace [9]. Lean has been recognized as the mainly
operational management strategy in manufacturing sector [10].The basic
principle of lean is responsiveness to change and waste minimization
[11].
Recently the agile community has started to look toward Lean
software development approaches [12], assaying the usage and benefits of
Lean principles known for manufacturing and production industry on
software development process. According to [13] there are claims that
Lean software development provides the theory behind agile practices
[12]. Many authors and practitioners see Lean software development as an
instance of agile methods [14]. From case to case, there are different
motives for implementation of Lean approach in software development.
Since, on the one hand, many large companies using Lean techniques in
their manufacturing operations have found it beneficial in many aspects,
and on the other hand, have recognized software used in their company to
be the substantial part of their products and business, they are seeking
to transfer their successful lean experience to the software developers.
The main benefits of Lean development are improved efficiency in
eliminating waste (including by that elimination of everything that is
not creating value) and increased efficiency in delivering value to the
customers. Additionally, pull system characteristic for Lean approach
has proved to be essential for process flow optimization, where system
can act as event-driven, producing and delivering what customer wants
and where he wants, instead of producing in advance for inventory.
Related to that, as the main overall goal of Lean development can be
identified achievement of continuous and smooth flow of production with
maximum flexibility and minimum waste in the process [15].
Lean concept involves three main elements: lean concepts, lean
principles and lean practices [12]. Lean concept is providing
organizations with possibility to "specify value, line-up
value-creating actions in the best sequence, conduct these activities
without interruption whenever someone requests them, and perform them
more and more effectively". There are five guiding lean concepts:
* Value and clear understanding of what it is;
* Value stream;
* Process flow;
* Pull system and
* Perfection and constant strive for it [16].
Concerning software development, the relevant items that can be
defined as waste that are tended to be eliminated are: "extra
features, waiting, task switching, extra process, partially done work,
movement, defects and unused employee creativity" [12], [13].
Poppendieck & Poppendieck [13] have adjusted lean principles
into lean principles relevant to the software development:
* Eliminate waste;
* Build quality in;
* Create knowledge;
* Defer commitment;
* Deliver fast;
* Respect people;
* Optimize the whole.
Furthermore, other authors widened the list of lean practices
relevant for software development [12]:
* Address bottlenecks;
* Defer decision making;
* Develop rewarding system;
* Workload levelling;
* Kaizen;
* Kano analysis;
* Use pull system;
* Kanban board;
* Limited WIP;
* Value stream mapping, etc.
One of the most popular instances of Lean approach is Kanban for
which it is considered to offer a less prescriptive element as compared
to Agile methods [17], [18].
2.2. Kanban
Kanban was developed by Taiichi Ohno, an industrial engineer at
Toyota, as a system to improve and maintain a high level of production.
It was one method to achieve Just In Time production. Kanban (kahn-bahn)
is a Japanese word literally meaning "visible record" [19]. In
manufacturing it refers to Kanban cards where one card is associated
with each piece of work. It represents one of the manufacturing
strategies and tools in Lean manufacturing systems where it may control
the levels of buffer inventories in the system to regulate production.
When a buffer reaches its preset maximum level, the upstream production
activities are not being continued for that particular part type, that
way achieving minimum inventory at any one time [20]. That is the main
Kanban feature that practitioners have recognized as significant for
software development. Furthermore, one of the most important premises of
Kanban is that system requires production only when the demand of
products is available. Kanban has proven to be useful and helpful tool
for an organization, enabling advantages from improvement of
productivity and minimization of waste [20], development of flexible
work stations, to minimization of waiting time and logistics costs [19].
In other words, the idea of Kanban approach is "to use visual
signals to synchronize the flow of work with process capacity, limit the
waste of work interruption, minimize excess inventory or delay due to
shortage, prevent unnecessary rework, and provide a means of tracking
work progress". Recently, with the application of Lean approach in
software development, previously described Kanban principles have been
tried to be "replicated" from manufacturing to software
development.
In software development, the main focus of Kanban is "to
accurately state what work needs to be done and when it needs to be
done, by prioritizing tasks and defining workflow as well as lead-time
to delivery"[18]. That means Kanban represents certain flow control
mechanism for pull driven development. In brief, Kanban aims to provide
visibility to the software development process, communicate priorities
and highlight bottlenecks which results in a constant flow of releasing
work items to the customers, as the developers focus only on those few
items at a given time [21]. Regarding that, Kanban systems in software
development have special significance from the aspect of scheduling
work. Related, Kanban systems bring differences compared to Agile
methodologies. They are focusing on continuous flow of work and
disregard fixed iterations. Kanban, as in the case of Agile
methodologies, sets the requirements and related work items and
implements them incrementally. However, instead of time-boxed
iterations, the Kanban team chooses those work items and starts working
on them when that is needed and there is capacity. The team develops
features one after the other and as soon as it is ready, the team works
only on one or very few at a time.
In other words, the Kanban in the context of software development
allows to the teams to visualize the workflow, limit WIP at each
workflow stage and measure the cycle time [22].
In their study [23] the authors identify main motivational factors
for adopting Kanban in software development projects:
* Improvement of team communication;
* Improvement of development flow;
* Reduced lead time;
* Increased productivity;
* Better transparency in organization and of work;
* Better control of flow; focus on flow and absence of fixed
iterations.
3. Case study and results
3.1. Methodology
The aim of this study was to introduce the adjusted Lean principles
which were seen as adequate for enhancing project agility (flexibility
and adaptability) and to test if these changes consequently result in
improved project team performances. In order to analyse and compare the
project productivity and effectiveness before and after Lean principles
were implemented in Agile software development process, available
metrics were explored and adequate metrics have been chosen.
Based on extensive literature review and project methodology
characteristics the most relevant and used metrics were selected for
this study:
* Team velocity: Represents the amount of work accomplished in each
Sprint expressed in story points [24], [25], [26]. This metric
demonstrates how much work development team can accomplish within one
iteration.
* Defects rate (count): can be both, internal process measure of
software testing and external measure as the number of defects
experienced by the customer [26], [27], [28].
* Rework items: count of items demanding follow-on efforts.
Firstly, the existing Agile Scrum method used by teams was analysed
based on previous 9 iterations. Following, the main challenges that team
members are facing are identified and used as input to define the
directions towards improved project agility and performances.
Based on the desired improvements, adequate modified Lean practices
were suggested and integrated into the Agile Scrum methodology. New
software development process was tested during 10 iterations and team
performance in both cases was compared using chosen metrics.
Additionally, data from sprint retrospectives, supporting programs and
notes from interview were analysed in order to get insight into the
project members' experience.
3.2. Analysis of applied Agile software development methodology
3.2.1. Agile Scrum software development process applied with the
project team
The goal of development process analysis was to get insights into
the software project management and identify improvement possibilities
for this project. Development team has 7 collocated sub teams, counting
all together 30 project team members. The final results of the projects
was 3D computer game. The team was using adjusted Agile Scrum
methodology, applying Scrum practices and artefacts presented in table
1.
Following, the described development process with Scrum methodology
is presented graphically (figure 1).
3.2.2. Team velocity analysis
Velocity was analysed and presented for each subteam and for the
whole development team. In this paper the planned and real velocity of
the whole development team is shown in chart 1.
Results demonstrate high number of unfinished story points per
iteration. With goal to identify more precisely potential problems
within each sub team, planned and expected velocity was additionally
analysed for each sub team separately. The major problem was in one sub
team where members could not accomplish even 50 percentage of planned
work. These events and delays in this particular sub team and similar
problems in other sub teams caused serious bottlenecks, since all
unfinished project tasks from one sprint need to be reallocated to the
next iterations. Furthermore, one of the reasons for appearance of
bottlenecks were interdependencies among tasks performed by different
sub teams. Team members defined the unrealistic work load as important
cause of poor velocity.
3.2.3. Analysis of defects and rework items
During the development process finished increments are regularly
tested manually and automatically, in order to determine the quality of
performed tasks and to detect necessary rework and possible
improvements. During the project duration project team has developed bug
prediction practice. Team is forecasting possible defects that will
demand additional human effort reducing the chances for bottlenecks.
However, analysis show many of occurred defects were not among predicted
once, enhancing the lack of experience and appropriate methods for risk
assessment regarding bugs and defects. Consequently, during iterations
few more complex tasks were blocked. The execution of those tasks has
been stopped in order to continue with the iteration which has resulted
in accumulation of unfinished sprint items.
To get deeper insight on team's performance, defects count and
rework items are demonstrated in chart 2. The number of defects and
rework items is represented for each of the subteams.
The highest number of bugs and needed rework is identified in Level
design team. The main cause is the intensive communication Level design
team had to have with 3D team members and Programming team, resulting in
lack of time for execution of tasks and inefficient communication.
3.2.4. Analysis of sprint retrospective data
Alongside the examination of velocity and defects rate as
indicators of project productivity and efficiency, data from sprint
retrospectives, meetings and project management programs were analysed
and the main challenges project team is facing during the Scrum
development process are defined:
* Incomplete tasks within a sprint caused by work overload of team
members, inflexible sprint duration ("time-boxed" iterations)
and complex sprint items (tasks). Furthermore, since Scrum methodology
do not allow changes in sprint backlog, change requirements occurred
during the iteration remain unperformed regardless their priority, or,
in case they are integrated in sprint backlog, other tasks are not being
postponed, again resulting in incomplete tasks within sprint. Finally,
there is lack of process transparency among sub teams which is essential
in this case where tasks are highly interdependent. Even though
time-boxed iterations can be motivational for team members to perform
their tasks on time, in this case this practice showed lack of benefits
for project agility.
* Poor effort estimation for certain user stories or its parts
resulted in unrealistic scheduling, causing either idle time or
bottlenecks.
* Frequent change requirements during the sprint that team could
not fulfil;
* Idle time for some team members: Team reported that certain
sprints were not optimized, respectively, work load among sub teams was
not balanced enough. Consequently, not rarely some team members were
required to wait for other team members to finish their task in order to
continue their work. Since sprint backlog is locked, team member waiting
for the upcoming task was not able to start new task, which resulted in
idle time.
* Bottlenecks: During the iterations high number of sprint items
were blocked in certain implementation phase. When certain problem
occurred, team members were most commonly postponing blocked items and
started new once without resolving issue, mostly because they were
impeded to dedicated additional time to certain task due to the fixed
iteration. In addition, poor effort estimation inflicted stoppage of
certain work items.
3.3. Identification of improvement directions
In the next phase of this study, adequate directions for project
performances improvement were defined. Observing identified challenges
project team is facing and summarizing abovementioned problems, it was
concluded that agility of the project needs to be improved in order to
obtain better project results. Project needs more flexibility in order
to successfully meet change requirements, better process optimization in
order to mitigate bottlenecks and idle time and more efficient visual
management. Main development process improvement directions proposed
were:
* Improvement of workflow optimization: Idle time and work overload
could be mitigated by achieving smoother development process,
respectively, by improving work flow optimization. In order to
accomplish that, it is necessary to plan work more efficiently, to have
more realistic effort and time estimation for each work item and clear
instructions in case of blocked tasks.
* Improvement of efficiency metrics based on experience from
previous iterations: Although it was observed that team members are not
able to finish the backlog items within sprints, sprint planning method
and velocity estimation was not changes during first 9 iterations. The
major cause for delays on project were unrealistic effort estimation and
complex work items. Thus, it is essential to dedicate attention to
examination of previous iterations and performance results in order to
obtain certain time norms and standards to tasks of approximate
complexity.
* Improvement of workflow transparency and team members'
communication: Blocked items and delays were also the result of
inadequate cooperation and communication mechanisms. In addition,
insufficient insight into the sprint progress of other sub teams caused
inability for some team members to plan their related work properly.
3.4. Integration of Lean principles into the Agile project
management methodology
Appropriately applied Lean development improves efficiency in
eliminating waste and increases efficiency in delivering value to the
customers [6]. In this case, it means Lean practices can provide project
team with possibility to detect which change requirements are important,
to prioritize them and include in their development process.
Additionally, pull system characteristic for Lean approach has proved to
be essential for process flow optimization, allowing the team to produce
and deliver what customer wants while mitigating bottlenecks. The main
overall goal of Lean development is to achieve continuous and smooth
flow of production, maximizing flexibility [12].
According to outlined above and previous chapter, identified
challenges and defined improvement directions, adequate Lean Kanban
principles are suggested to be implemented and combined with existing
(figure 2):
* Constant backlog planning and prioritization;
* Introduction of "pull" system;
* Introduction of "ready" queue;
* Work items of similar complexity;
* WIP (work in progress) limits:
* Improved work flow visualization;
Constant backlog planning and prioritization: In Kanban Lean
software development the sprint backlog is not locked. The backlog
consists of items prioritized and chosen by creative director and game
designer. This way, changes during the sprint are acceptable and idle
time avoided, since as soon as a team member finishes one work, in case
there is free capacity, employee pulls next items and works on it.
From "push" to "pull": The system implies that
work is pulled as and when needed into a queue, unlike the approach used
in a traditional Scrum where all the work to be completed within a
sprint is assigned in the beginning of the sprint to the sprint backlog.
Introduction of "ready" queue: This ready queue contains
items that are pending from the backlog, but have high priority and are
chosen by product owner.
Work items of similar complexity: The suggestion is to decompose
all of the work items on tasks of similar sizes as much as possible.
This way during the following iterations it is possible to establish
approximate time standards for familiar tasks. Furthermore, team members
will have more clear insight into the work scope and will be able to
improve effort estimation.
WIP (work in progress) limits: This principle implies limiting the
Product Backlog Items (PBIs) that are in progress at any point of time,
including the sprint backlog. The idea is to keep team focused on
completing work at hand rather than starting a new task. This means once
a limit is reached within a particular stage of the workflow, rather
than starting working on something new, it is time to help someone else
within the team. This will ensure that the team's work flow becomes
smoother and no stage becomes a bottleneck.
3.5. Results
The effects of proposed Lean Kanban principles on team performance
were measured during 10 two-week iterations. During iterations before
Lean principles were introduced, team was defining velocity as team
capacity to perform certain number of story points within one sprint.
Those story points weighted determined coefficient representing effort
necessary for completing the task, while each item weighted certain
number of those story points. In such a way,for every sub team expected
velocity, i.e. number of story points is plannedin accordance with the
number of sub team members and work complexity. However, sprint items
could comprise significantly different story points. In the case of Lean
development, work items contain same number of story points since one of
the suggestions was to reduce work items to approximately same-size
items.
It is noticed that modified agile methodology has resulted with the
first two iterations with low team velocity. However, after the third
sprint team accomplished significantly better velocity than with
previous methodology. According to team members, the velocity of the
first three iterations is the result of changes and new working
practices which have required team members to adapt and learn. Planned
and real velocity of the whole development team is shown in chart 3.
As in the case of initial software development process, defects and
needed rework were monitored. The status of defects count after 10
iterations is shown in chart 4.
Although relatively high in first iterations, after the third
sprint the number of defects and items demanded to be reworked has been
significantly lower than in the first case. Team has shown more
moticeable improvement regarding work quality compared to velocity
meloriation. Defect and rework rate was reduced for even 50 percentage.
Team members emphasized that this results was mainly caused by decreased
pressure due to the implementation of constant backlog grooimng practice
and work in progress limitation.
Furthermore, during interviews and sprint retrospecives, team
members pointed out that adeqaute usage of metrics and visual management
tools facilitated communication and made it more transparent, enabling
better and faster problem solving and task management. Rework was
reduced, since the quality of work preformed was monitored and
controlled during the whole sprint not only during the demo sessions. In
addition, team was able to accomplish more user stories and improve its
productivity, since metrics enabled more realistic estimation of work
items planned for one sprint.
4. Discussion and conclusion
The aim of this study was to test the influence of Lean practices
on project performances and project agility, i.e. flexibility and
potential to adapt to changes.
The main challenges team using Agile Scrum approach is facing were
identified and based on results suggestions for the improvement were
created.
Scrum methodology, as other agile methods, is not being implemented
in the same manner in every organization. In opposite, each organization
adjusts methodology based on their specificities, project and team
characteristics. Since the product of this project is alpha game,
constant feedback from publisher and customers are included during the
whole project duration. Thus, change requirements were highly frequent.
Scrum methodology implies that sprint backlog could not be changed
during the iteration, team was unable to fulfil new requirements on
time. Consequently, the project milestones were often not accomplished,
postponing the finish of the project. Furthermore, team consists of very
different profiles of employees (artists, programmers, philosophers,
etc.), which makes development process management more complicated and
demands different techniques for effort management.
By adding adequate Lean Kanban principles based on needs of project
and team, game development process was improved.
Pull system and constant backlog grooming enabled team to be
responsive to the change requirements without causing delays and
unfinished items within sprint.
WIP limits ensured that team members are focused on tasks they are
executing at the moment and on solving potential problems and blocked
items immediately, consequently decreasing the occurrences of
bottlenecks.
The practice of decomposing sprint items into similar-size tasks
improved effort estimation process and facilitated the sprint progress
monitoring. Additionally, it enabled team to establish average lead
times for future iterations.
Considering the company, project nature, team structure, and obtaie
results, further suggestion from authors is to completely eliminate
sprints in order to optimize the flow additionally and improve capacity
to react fast to the change requirements. Eliminating time-boxed
iterations the optimization of work flow would be even more improved due
to more flexible and event-driven work planning. Responsible project
leader or product owner should continue grooming backlog and
prioritizing items.
DOI: 10.2507/28th.daaam.proceedings.093
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Caption: Fig. 1. Graphical presentation of Agile Scrum software
development process applied with the project team
Caption: Fig. 2. Lean development principles suggested based on
noted challenges and defined improvement directions
Caption: Chart 1. The planned and real team velocity
Caption: Chart 2. The average number of defects and rework items
per each team
Caption: Chart 3. The planned and real team velocity after
introduction of Lean principles
Caption: Chart 4. The average number of defects and rework items
per each team after introduction of Lean practices
Table 1. Existing Agile Scrum practices and artefacts in case company
Existing Scrum practices
within project team
Product backlog In this case backlog product
is "Game design document"
which contains all game
chapters with their rough
description. The backlog items
are prioritized from the
beginning of the project.
Sprint and sprint There are two-week time-boxed
backlog iterations. Sprint backlog
items are elements and objects
of certain game scene. During
the sprint duration, each
member executes sprint items
which go through different
process phases.
Sprint planning and There is no traditional sprint
effort estimation planning. Since sprint backlog
is made of elements and
objects of one scene (small
user stories), there is no
need for sprint items
planning. However, the team is
revising the items together in
order to discuss if the given
effort estimation is realistic
Regular virtual For monitoring project
board and burn down progress Trello program is
charts being used with integrated
virtual table. Also, the
program provides team members
with burndown charts showing
remained work within
iteration. Overall, these
artefacts are helping team
members and product owner to
track the progress of the
sprint.
Scrum meetings As the goal have discussion
about necessary corrections,
current problems and further
instructions.
Sprint retrospective Scrum retrospective helps team
improve their further
iterations. It is being
conducted with aim to
constantly improve following
sprints.
Sprint demo It represents the official
representation to the product
owner of functional sprint
increment and official
approval of sprint increment.
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