LeanMan Grand Simulation Package

$1,838.95

 

The LeanMan Grand Simulation Package is a reduced cost recombination of the Deluxe Car Factory Simulation plus the VSM, the Kanban and the Heijunka simulation events conveniently packaged into two double-deep containers. This combination package saves more than $100 than when items are purchased separately.

Package Contents:

Two Car Factory Kits, the VSM Upgrade, the Kanban Upgrade and the Heijunka Upgrade materials, all packaged into two double-deep containers. Includes two Stopwatches, two wet-erase markers, Laminated Kanban material control cards, Laminated Participant placemats, and all simulation materials and forms. Files are provided on DVD and USB Flash Drive.

Included in 2017 are the Large Group Simulation Package presentations and printable file materials on the DVD at no additional charge!

LeanMan Grand Simulation Package

The LeanMan Grand Package provides all the necessary materials to completely explore the Lean Manufacturing implementation, with an executive overview and events that range from beginner to advanced. 

Deluxe Simulation

The Deluxe Kit includes the advanced 6-exercise TPS simulation event with Financial Metrics. This set of exercises follows closely the TPS Paper Airplane Simulation, but without all the wasted paper.

The deluxe kit also includes the Lean Principles Training Guide CD: Learning to See the Waste. This Power Point presentation and simulation is perfect for introducing executives and others to the value of lean, the entire presentation and two simulations can be completed in under one hour.

This deluxe kit will provide immediate presentation and simulation exercises suitable for all management levels including top management and associates. It then delves deeper into the art of Lean for those associates that require hands-on practical experience. Take a look at the Deluxe Car Factory Kit - and check out the details.

Door - to - Door Value Stream Simulation

The VSM Upgrade adds a 9-step transformation using the concepts of the VSM Value Stream Simulation.

For a full description of the VSM capabilities and material items, please see the Deluxe Plus VSM Car Factory Kit - and check out the details.

LeanMan-Deluxe-Plus-Kanban Simulation

The LM Kanban Simulation upgrade supplies the additional materials that turns the Grand Package into a fully integrated customer-driven value stream from customer to factory to supplier.

This simulation training will help participants understand how lean philosophy and techniques can be applied in a customer-pull product flow utilizing kanban cards, signaling devices and heijunka planning to control flow and inventory levels.

The LM Kanban Simulation is presented in four events - all four are a full value stream and utilize kaizen and inventory metrics to analyze flow; the last two events utilize the heijunka planning method and heijunka box to sequence flow. All events calculate the Earned Value; Margin as a percent of sales; and Inventory levels. All four events also introduce Little's Law metrics equation TH = WIP x CT. See Fun with Little's Law. For a more complete description of this simulation check out the Deluxe Plus Kanban Simulation Package full Value Stream lean training event.

Heijunka Box and Simulation

The Heijunka Upgrade simulation training will help participants understand how lean philosophy and techniques can be applied in a mixed-mode product cell to maximize customer value, minimize waste, reduce costs through workplace organization and visual controls, implement one-piece flow, instill quality at the source, and synchronize to customers needs using pull scheduling.

For a full description of the Heijunka capabilities and material items, please see the Deluxe PLUS Heijunka Lean Factory Simulation Package product description Deluxe Plus Heijunka Simulation Package

The files are provided on DVD and USB Flash Drive, and include additional free bonus presentation materials. These short presentations provide supporting concepts and training necessary to fully implement the lean principles into your organization.

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

Included files 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 5-S 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 5-S are the basis for two fun and challenging games available from The LeanMan. See the tab Team Development: 5-S Game Set. 

  • 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 5-S 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.

Compatible Simulations

The LeanMan suggests using the LeanMan Grand Simulation Package in the following simulations:

Learning to See the Waste

This executive level 2-Step simulation is the simplest event to run but packs a big WOW factor. It requires just one Car Factory Kit per team. Plus, with the laminated participant instruction placemats, it's so easy to perform that single person can easily facilitate five or more teams, making it great for large audiences and conventions.

  • Group Size: 5-8
  • Duration: 100 min.
  • Steps: 2
Car Factory Simulation

This 4-step simulation uses one Car Factory Kit per team, and a single facilitator can easily run 2 or 3 teams in parallel for a little competition and metrics comparison. This simulation event is also provided as an editable set of files on CD that allow customization to the facilitator's specific target training needs.

  • Group Size: 5-8
  • Duration: 100 min.
  • Steps: 4
Large Group Simulation

Purchased as a separate supporting product (it is included in the Grand Package), this simulation is used with multiple Car Factory Kits to expand the event size to accommodate larger groups for an introductory Lean experience. The 4-step simulation is designed as an introduction to Lean for variable sized groups of participants in the four main flow methods.

  • Group Size: 5-39
  • Duration: 60-150 min.
  • Steps: 2 or 4
TPS Simulation

The Toyota Production System (TPS) simulation is a 5-step event which uses the training methods generally recognized as the Toyota method for introducing lean flow. This method focus more on flow and eliminating process waste and less on reducing the number of human elements in the process.

  • Group Size: 8-12
  • Duration: 110 min.
  • Steps: 5
VSM Simulation

(Value Stream Map) This 9-step event focuses on each of the nine point processes in the value chain from customer order to customer delivery, one process at a time. Each exercise introduces lean techniques such as kanban material and visual signal devices, use of target tracking reports, kaizen forms, and continuous improvement metrics. This simulation exercise also provides an excellent basis of understanding for Value Stream Management training for the LEAN office.

  • Group Size: 11-15
  • Duration: 280 min / Continuous Loop
  • Steps: 9
Heijunka Simulation

The “Leveling the Waves” presentation presents an alternate way of approaching the function of master scheduling and planning for a lean manufacturing environment. This presentation event is part of the Deluxe-Plus Heijunka Training Package.

  • Group Size: 8-12
  • Duration: 190 min.
  • Steps: 3
VSMgt Service & Repair Center

Purchased as a seperate supporting product, this 3 step simulation exercise will explore the service side of the car factory, so instead of assembling new cars, we repair them. Value Stream Management concepts are used to improve flow door-to-door in this unique and fun exercise. This simulation requires purchase of at least one of the LeanMan Car Factory Kits or Deluxe Packages.

  • Group Size: 9-12
  • Duration: 140 min.
  • Steps: 3
Kanban Simulation

This four-step Customer-Pull event explores the flow control differences between a single kanban card and dual kanban card replenishment system with random demand in a full value stream simulation.

  • Group Size: 8-12
  • Duration: 260 min.
  • Steps: 4

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