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real life training simulations

Six Sigma – iSixSigma Forums Old Forums General real life training simulations

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  • #52134

    cheezer
    Participant

    All,
    Just wondering- has anyone on the forum ever developed a “real life with actual product” simulation exercise for lean/TOC training? I’ve had this request from multiple leaders at companies I’ve worked for and have never been able to do this in a practical manner. I’ve also asked dozens of consultants and program leaders if they’ve been able to accomplish this, but none have.
    I’m currently implementing lean with a TOC bent at a company. I have multiple simulations I’d like to use which I can do in a couple hours (the same ones everyone uses) which easily show the waste associated by not following the “drum” and advantages of smaller batches/lower inventory/standardized work. The top guy has asked “why can’t we use real product in order to do the simulation?” I’ve tried to explain to him that our cycle time of 3 weeks (on our fastest valuestream) is not practical for a training exercise. If we could use actual product for a one or two day training, we would’ve already implemented the same product flow into operations for a one or two day cycle time, so they wouldn’t really need me to do training.
    So, has anyone accomplished this; you do your training using real product in the real production system? Just wondering, as I’ve not heard of this being done anywhere, but I bet CEO’s everywhere have asked for it.
    Thanks,
    cheezer

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    #182932

    GB
    Participant

    “Real-Life Training Simulation is an Oxymoron”…

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    #182933

    GB
    Participant

    “Real-Life Training Simulation is an Oxymoron”…

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    #182940

    cheezer
    Participant

    Thanks, HBGB, I’ll use that.

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    #182948

    BTDT
    Participant

    Cheezer:Have a look at some of the classical supply chain simulations impelemented at Forio.com. These are the “beer game” simulations run at MIT for years. They work well to illustrate the “bull whip” problems of slow communication in a supply chain. You can also have a good discussion about WIP and “pull” vs. “push”.If you are so inclined you can input a model of your own supply chain from STELLA and have the class interact with a facsimile of your own business.http://forio.com/harvard-root-beer-game-production-distribution-simulation.htmhttp://forio.com/nearbeer.htmCheers, Alastair

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    #182962

    MBBinWI
    Participant

    Sounds to me like your “top guy” is more of a “if it’s not my product, I don’t believe it” type.  If so, no simulation is going to make him a believer.  If not, here are a couple of simulations that might prove useful ( http://www.ganesha.org/leading/toc.html , http://www.goldratt-toc.com/08/default.asp?P2i=4 , http://bottleneckbusters.com/blog/2006/04/the_effective_use_of_simulatio.html )  I also have a version that uses lego’s, but I’ll need to find it to get the name of who made it.

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    #182974

    cheezer
    Participant

    You pegged him, MBBinWI. If it’s not his product he has the attention span of my 2 year old. I have all the simulations mentioned by others, I just don’t have a simulation using our exact product, which is what he requested. I was wondering if anyone has ever accomplished this. As I noted in my original post, if we could do it in a simulation we wouldn’t have issues on the plant floor.

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    #182980

    Pal
    Participant

    Agree that “real life simulation” is an oxymoron. 
    Cheezer, what you need is a case study using your customer’s own product/process (for relevance) but that also compresses time, cost, risks, etc. associated with “real life” so you have the effectiveness and teaching points of a simulation.  Have you considered developing a simulation by using an in-house product/process that has been improved?  Utilize data from the prior state (unimproved) process, the mapping, analysis, etc. and improvement activities used to arrive at the future (now current) state.  One word of caution:  as the processes become more real/close to reality, the more the students will argue over whether the “simulated” process is indeed accurate.  Sometimes it’s better to be quite wide of the mark rather than be close to it.  Last observation:  if the student (or supervisor) can’t draw an analogy, they probably shouldn’t be students. 

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