Module 1
Lean Thinking
Introduction to Lean Culture & Philosophy
Lean Simulation Game:
„Lean Factory”
Description
Lean Thinking is a passionate belief that there is always a simpler better way!
Since Lean is a management philosophy aimed at eliminating everything that does not bring value from customer point of view, we focus on value stream as a primary work unit looking for continuous improvement.
Lean Thinking constitutes a huge paradigm shift. Breaking through to sustainable change in the way we think, we behave and we work is the key to success. How to approach it you will learn from the LEAN Thinking sessions.
LEAN Factory Simulation Game.
This is the best way of implementing a LEAN Philosophy and Culture. This is a universal game, entirely reflecting real life production conditions by offering a lot of fun.
The simulation includes such processes like planning, manufacturing process, changeovers, materials flows, warehouse, shipping, supplier & customer issues, etc. The primary objective of the game is to lead a seamless transformation from a traditionally managed company to a LEAN factory.
As a result of developing solutions for improvement and implementing LEAN techniques, participants will be directed towards the main goals of the game: achieving a 100% customer satisfaction and making the company “rightsized” to obtain operational profitability.
Learning Objectives
- „Eyes opening” session. Why do we need Lean? How to switch to Lean Thinking?
- Explain the benefits of being Lean and how Lean improves business performance.
- Define what is value and what is waste. Learn how to distinguish between value and waste.
- Define the critical success factors in sustaining a Lean Culture.
Program Outline
Lean Thinking (2-3 hours).
- Understanding Lean Philosophy
- Becoming Lean Thinker
- Lean Principles and Approach to Creating Customer Value
LEAN Simulation Game (5-6 hours):
- 15 active game participants. More can participate as alternative observers.
- In four rounds you will lead the organization to Lean Factory.
- Using Lean Thinking and all Lean tools & techniques you will run brainstorming and implement solutions to achieve the objectives.
- You will learn and practice such Lean techniques as Kanban Pull Flow, Continuous Flow, SMED, Process Balancing, Process & Organization Streamlining, Reducing Waste
- You will measure all KPI after each round, incl. Customer service rate, WIP inventory level, unit cost, productivity and profitability!
Methodology
Multimedia presentation, short lectures, individual exercises, group activities and discussions and Q&A . Simulation and game exercises!
Recommended Audience
Every member of the organization, from C-level to team leaders and operators since ultimately everyone should participate in the system.