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Ideas for Exercises/Simulations for Lean Training?

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  • #41987

    Ken Theriot
    Participant

    I am putting together a 4-day training course for Lean facilitators.  I have a couple of exercises/simulations aleady, but I am looking for ideas for more.  What are some ideas folks have to illustrate the main Lean concepts?  I use the dice game for supply chain/push/pull illustration.  And there is another one that demonstrates value stream/ flow cell benefits.  But I really want to make this training hands-on, and am looking for exercises to demonstrate 6S, standard work, takt time, value stream mapping etc. 
    Thanks!
    Ken T

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    #132304

    Heebeegeebee BB
    Participant

    For manufacturing, I’d suggest an “Aggie-Boat” (AlliedSignal), or “Traumahawk” (Raytheon) type simulation, in which you set up nasty factory conditions for the baseline run.   In between rounds, focus on improvement concepts/methodologies and let the team run through DMAIC to implement process improvements.
    good stuff.

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    #132306

    Mike Carnell
    Participant

    Ken Theriot,
    Check out the dice game that Goldratt uses (rolling dice and moving material from one perso to the next). It takes about 45 minutes to 1 hour and you can drive the idea of bottlenecks and variation reduction in one exercise.
    Just my opinion.
    Good luck

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    #132317

    Lean Guy
    Participant

    Where could I find more info about “Aggie-Boat” (AlliedSignal), or “Traumahawk” (Raytheon) type simulations? Web site?

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    #132320

    Heebeegeebee BB
    Participant

    In a nutshell, you set up a facotry consisting of tables arranged rather haphazardly with the baseline run exhibiting horrendous, yet realistic conditions encountered in real factories. (i.e. excess inventory, inept management, unbalanced lines, rigid wasteful processing,etc…)
    You run the round, collect/analyze the data (COPQ) and discuss potential improvements(Line0balancing, footprint reduction, Muda reduction/elimination, Kan bans, etc…)
    Run round two, debrief and run a final round, all the while using DMAIC/PDCA cycles. 

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    #132331

    Ken Theriot
    Participant

    Thanks.  I already do the Dice Game.  Are the Aggie Boat and Traumahawk exercises described anywhere, or are they proprietary?  I’m really just sort of looking for simple, quick simulations/exercises, which I imagine are fairly numerous.  I hear tell of a lego simulation.  Stuff like that. 
    Ken T

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    #132334

    Heebeegeebee BB
    Participant

    They are proprietary, but you hit on something w/ the legos.   Both exercises use legos, duplos or bristle blocks.   Center the exercise around the production of an item comprised of multiple sub-assembly builds.   Bombardier put a really good exercise together to take into account, transactional environments.   Their product was a service.
    I’d suggest designing your own based on 3-ten minute rounds with “teachable moments” designed into the breaks between rounds.   It doesn’t matter what you have them build, in fact, the sillier, the better.
    The take-aways I focus on  are:
    data collection
    DMAIC/9-step model/PDCA
    FMEA
    Facilitation/team building
    SPACER
    MSA
    NEM
    DOE
    COPQ
    Lean concepts

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    #136220

    Lean from China
    Participant

    Anybody here got a detailed guidelines for the Dice Game?
     
    please email it to me at [email protected]

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    #136827

    ProLean
    Participant

    I would appreciate if i can get the dice game information too. Thanks.

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    #136837

    Adam
    Participant

    We have a few different games and simulations that we use when we teach our classes. If anyone wants info, email me at [email protected]

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    #136839

    Brent
    Participant

    Ken,
    If you don’t mind spending a little money, check out The Lean Man.  He sells wooden car assembly kits for Lean training.  I have no affiliation with him, but have seen these products in action. 
    I have participated in various Lego exercises, and would report that they must be carefully orchestrated and choreographed to provide proper learning.  They can range from simple to very complex.
    One of the more impressive learning Lean demos involves a simple college logo being written on index cards and stapled.  Again, can be simple or more complex.  The best thing is that it’s inexpensive and quick.
    Hope this helps!

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    #136841

    Schuette
    Participant

    I have see a lean simulation specifically for the financial services sector.  Similiar to a wooden car assembly simulation, it simulates check processing from receipt to cash letter clearing to fed  using wooden (eg. proof encoding, sorter, low speed sorter).  Also can be used for lockbox, a/p, payroll, etc.  He can be reached at [email protected]

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    #155368

    Alec
    Participant

    If someone has a full set of old Allied Signal Aggie Boat training material, I would be very interested.    I have a lot of the Blocks,  and a lot of the material,  but not the full set.

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