“Lean game”, is a game based educational, it is designed to illustrate the improvement process using Lean in production and the use of Lean Tools. How to work smarter by removing that in production, what does not add value to the product/customer.
The game begins with a theoretical review of a number of tools in LEAN. After a break the production of torches starts. The torches are assembled in 5 stations and all participants to have a role, such as production manager, operator, fork lift driver, quality controller, customer, etc. After 12 minutes of production, the result is evaluated and the profit of the factory calculated. The group may then choose among a number tools for improvement and implement improvements in the torch production. After that, the production starts again, and the result is measured. It gives it a direct feedback of the changes made.
The game runs in 5 rounds and takes about 8 hours to complete including theory.
This workshop is addressed to all staff at the company and does not require any special Lean knowledge in advance. Each tool/method is explained and when implemented, the participants start to understand them.
CONTENT
•Introduction and Presentation of Lean methods. (approx. 2 hours)
• 5 rounds of the Lean game with improvement actions between
• Summary and discussion about the business effects of improvements, effects of different Lean tools, which order to implement etc.
Learning by doing is the most effective way of learning. Even if this is a simulated work environment, many of the problems the participants meets in their daily environment is illustrated and solutions suggested. Such as:
•Set up time - SMED
•Quality errors - RFB, Poka Yoke, supplier development and Andon
•Efficiency – Layout, U-cell , Line production, 5S, Standardized work, and work balancing.
•Improvement- Team organization, Kaizen, and PDCA.
•Management – Analyze methods, spaghetti chart, visual control, motivation, daily meeting and implementation strategy.
•Effect on company results – revenue and cost follow up
•Product design – QFD and DFA





