The Companion Lean Factory Simulation Car Kit builds upon the Basic Car Kit by providing some easy to facilitate Lean Principles training exercises and support material files.
The Companion is recommended as an additional kit for those who have purchased the Deluxe Kit and wish to add capacity to the simulation sessions or train multiple teams for a little competitive fun. The Companion includes the LTSTW laminated participant placemats to help make facilitation easier. Two Wet Erase Marker pens are included to record metrics.
Note: A set of TPS laminated participant placemats are included, without instruction, to facilitate those customers who own a Deluxe Kit and desire to add the Companion Kit and run two TPS teams in parallel.
Each kit comes with the files for the training setup guide, plus instructions for the standard 4-step Car Factory simulation and the Learning to See the Waste (LTSTW) simulation.
The first Car Factory event, MRP Batch ‘n Queue, shows the effects of moving large batches of product through several stages.
The second Car Factory event, adding Continuous Flow push, shows the effects of overproduction which simply means producing more sooner or faster than the next stage requires.
The third Car Factory event, adding a kanban pull signal to Continuous Flow, begins to coordinate each team member, controls inventory better, and shows where some obvious balance opportunities exist.
The fourth Car Factory event, adding local control with point-of-use inventory and built in quality, shows the advantage of becoming lean.
There are two painted car bodies which can be used to introduce mixed mode production into the work cell. Plus, two of the "Mole" cards are included to provide velocity timing of the color cars through the process for easy metrics. The "Mole Card" is used to record the time the car arrives at each station from Stock Kit to Finished Goods.
The kit includes a set of 8.5 x 5.5 laminated participant placemats for the Executive Level two-event simulation Learning to See the Waste. This short but powerful simulation is a perfect first time event to showcase the power of lean mfg. It packs a real W O W factor for first time lean participants.