Each Deluxe Kit contains two Microsoft Power Point training presentations on CD. The first is a 4-step simulation training setup guide, which the trainer can customize to fit the specific training situation being taught, plus some forms for tallying metrics.

The Lean Factory Simulation training begins with the Batch ‘n Queue method based on Adam Smith’s division of labor principles. These were later solidified by Frederic W. Taylor and presented in his 1911 book “The Principles of Scientific Management” (New York: Harper & Brothers). Taylor’s methods became the bedrock for production flows around the world, where companies learned to divide functions into small departments, each organizing their activities into batch processes to optimize their own independent needs and goals.

The second presentation is a history of the manufacturing methods leading up to Lean Mfg., and provides detail concepts behind each of the training simulations. Both presentations may be customized to include your company logo and edited to focus on your specific needs.

The batch process is nicely presented in the New Manufacturing Challenge: Techniques for Continuous Improvement by Kiyoshi Suzaki (The Free Press, 1987), and it is Suzaki’s model that becomes the first simulation event step.

The next event step transitions to the techniques of one-piece cellular flow with MRP push; then continuous flow with kanban signals; and finally ending with a lean flow using a demand pull system.

Along the way, additional lean concepts are layered onto each event, such as Value Stream Mapping, learning to see waste with the NVA test, and more. There are four main flow concepts presented and fully described in the kit, plus many suggestions for training the participants to think lean.

The simulated product is a small car that is easily assembled and disassembled, in a take along package that provides the trainer with an excellent reusable lean concept training tool. The LeanMan Deluxe Lean Factory Simulation Kit provides enough materials to train an average class of 5 to 9 individuals, with opportunity for each individual to have hands-on participation time in at least one event. Add Companion Kits to increase class size as needed, or to provide additional materials to extend the length of each exercise training period. See the LeanMan Large Group Simulation under the Expansion Products tab of this web site.

The Deluxe Car Kit includes materials to simulate the influence of non value-adding activities like fixturing and containers that are returned upstream, and the impact of material defects to flow. Certain components of the toy car have been selected to emphasize naturally occurring human influences that contribute to a learning curve, while other influences are inserted by design. The importance of having both components of variability, natural and imposed, is essential to presenting a true simulation or real shop conditions. The result is a design that closely mimics real factory conditions with very realistic metrics from team to team.

Note: see Why not Legos? under Lean Thinking: Past Simulations.

Each of the 20 assembled cars is easily disassembled and all materials are completely reusable. For larger class sessions, simulations may be run in parallel for comparison, or may provide for some competitive continuous improvement exercises. A second kit is recommended for large class sizes or high frequency training needs, and all component parts are fully interchangeable kit to kit.

There are also observation roles participants might fill to gather information on each flow method as it unfolds. The Deluxe Kit includes the 10-Second Test waste manager along with the facilitator notes for the TPS 6 exercise event that leads from a 5-pc Batch'n Queue to 1x1 Lean Flow with 2-Bin Kanban material. Each exercise ends with Financial Metrics and an analysis of the 8 wastes. These exercises and observations provide the class with discussion material that can be used to explore:

• Value Adding and Non-Value Adding activities associated with each flow type,
• Effects of each flow on quality,
• Ideas that form the basis for continuous improvement Kaizen event ideas
• Certified Assembler concepts
• Work Balance and Takt Time concepts
• Point of Use (POU) shop inventories methods
• Value stream mapping techniques

Companion kits are available for adding additional training capacity to allow two or more teams to run the simulations simultaneously for a bit of competitive fun. The Companion Kit contains all of the hardware material items from the Deluxe Kit, but lacks the PowerPoint presentation materials.

The presentations may be used as is, or edited for your specific training need and audience.

Included on the CD are:

• The Five Principles of Lean - 8 slides
  This presentation can be used as a baseline for introducing the student to the five principles of lean as outlined in the book: Lean Thinking by James Womack et al. Edit the PowerPoint slides to add focus for your specific training event.

• 14 Philosophies behind TPS - 15 slides
  Excerpts from The Toyota Way by Jeffrey Liker, this presentation provides the 14 guiding philosophies developed by the Toyoda family and other contributors that are the foundation for the Toyota Production System.

  Note: The concepts and terms presented in The Toyota Way book are the basis for two fun and challenging games available from The LeanMan. See the tab Team Development: TPS ToyodaWay Game Set on CD.

• 5-S for Lean - 35 slides
  This presentation can be used as a baseline for a 5-S program. It contains the basics for understanding 5S and a great starter program to set your workplace in order and prepare it for Lean. Edit the PowerPoint file to suit your needs.

  Note: The concepts and terms of 5S are the basis for two fun and challenging games available from The LeanMan. See the tab Team Development: 5S Game Set on CD.

• Visual Control for Lean - 13 slides
  This presentation can be used as a baseline for a Visual Control program to provide visual communications in the shop area. Coupled with the 5S presentation, it sets the stage for powerful and fast team communication so everyone knows what, when, where and how the product flows. Edit the PowerPoint slides to suit your needs.

• Visual Systems for Lean - 46 slides
  This presentation can be used as an introduction to Visual Systems and 5-S. It focuses on the concepts of seeing new meaning behind everyday sights, and works well to support The LeanMan Learning to See the Waste and The LeanMan Developing Lean Eyes presentations. Edit the PowerPoint slide to add photos from your own workplace.

The LeanMan 26 question Lean Self-Assessment Tool is also provided to help you assess your team's present Lean maturity level and readiness to implement the principles of lean into your organization.