The Lean Factory Simulation 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. This 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. (The Deluxe Kit provides all this history and more in greater detail in the Power Point training presentation included on CD)

The simulations then progress through the techniques of one-piece cellular flow, continuous flow with kanban signals, ending with a lean flow using a 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, with four variations of each type described in the kit, plus many suggestions for training the workers to think lean. Please see the Suggested Training Syllabus on the References tab.

Key learning objectives of the simulation

• Understanding Lean concepts of one-piece flow, pull systems, inventory reduction, and more
• How production flow has followed batch ‘n queue over the last 100 years, and why change is needed
• How to see where waste and inefficiency exists in each type of flow
• How line imbalance and inventory stockpiles affect the customer
• How to see the whole value stream
• How to optimize the efficiency of the whole stream versus the efficiency of the individual process
• How to identify Value Adding and Non-Value Adding activities
• How to seek continuous improvement, one step at a time
• How to Think Lean