Lean simulation helps break down employees’ natural resistance to change, making it a practical and entertaining way to introduce new concepts, open constructive dialogue and demonstrate the positive aspects of well-planned directed change. Employees involved in this simulation see why lean production methodologies is necessary. It helps to remove their fears regarding change and encourage them to identify non-value added activity.
Using this fictional aircraft factory simulation also specifically teaches advanced manufacturing practices, including:
- The benefits of cellular manufacturing over traditional plant layouts
- The effects of rapid throughput with traditional manufacturing
- Work-in-progress as a manageable asset
- Inventory risks
- Independent cross training
- Flexible workforce (load leveling)
- One-piece workflow with a pull system
Participants operate simulated workstations along the assembly line in their imaginary aircraft plant. The four-phase simulation begins with participants producing airplanes using a traditional plant layout. In phases two and three, they redesign their work area into a cellular layout and learn to utilize one-piece workflow with a pull system. In the final phase, they experience the concepts of a flexible workforce and load leveling. Supplier problems, labor skills, deadlines, quality control and other real-life situations have been incorporated into each phase of the simulation. Each phase lasts six minutes with time for comments and discussion.
Click below to watch a video demonstration.
For more information, or to schedule a Lean Simulation at your organization, please contact Wendy.