2. 1
TRAINING CONCEPT
The purpose of developing this training is to get hands on experience with the concepts of lean manufacturing and
be able to use the tools in a simulated assembly line that is made out of legos. This training allows the employees to
grasp and understand tools that will allow them to improve the Quality of the product, Safety of the work
environment, meet Deliveries and gain Customer Satisfaction.
Lean Manufacturing tools that are used with this exercise:
Current State Value Stream Map
Waste Analysis (8 types of waste)
Brainstorm Solutions to Improve Process efficiency (Kaizen)
Future State Map
Pull Systems (Kanban) – Lead time vs Response Time
Flow (Spaghetti Map)
Takt Time Chart / Cycle Time Chart – Balance Workload
Standard Work
5S
The training is aimed for those companies that are embracing a Continuous Improvement culture at all levels of their
business, the training was also developed for different type of learners like Visual, Verbal and Kinesthetic.
TRAINING DEVELOPMENT
The training was developed by using a lego set that simulates an assembly line. The assembly line becomes part
of the learning experience for learner to identify process waste during the assembly simulation.
The training consists in a combination of learning through powerpoint slides, a quantity of 3 rounds of hands on
experience and working as team to brainstorm solutions to improve processes from round to round.
An agenda was also prepared ahead of time to cover timing, topics and facilitator notes.
Equipment needed: Conference Room with projector and MS powerpoint. A Conference Room to setup the tables
for running the exercise.
3. 2
TRAINING PILOT WITH ROC INDUSTRIES INC.
The training was piloted with employees from ROC Industries Inc., that consisted in employees from the
departments of engineering, supply chain, warehouse, manufacturing and assembly. They were able to use the tools
to get them from round to round and achieve the goals of the exercise which are delivering 10 assemblies in 10
minutes without any quality issues, miss deliveries and no safety accidents.
The following depictions show some of the tools used and interactions during the exercise:
5. 4
FEEDBACK FROM THE EXERCISE:
The employees finally understood what “pull” meant vs push in an assembly environment, by actually
setting up kanbans and rules of engagement on when to pull to support your downstream customer.
They felt that this exercise allowed them to be challenged into brainstorming solutions to meet the
customer requirements, they understood how to balance the work using the takt time chart.
They understood the concept on when to put strategic buffers (Supermarkets) vs balancing idle employees
in the line in a particular bottleneck; this created great discussion around inventory values and labor costs.
The exercise was fun and they enjoyed the fact that it was an unusual type of training.
This simulation forced them to work as a Team and they felt a high level of accomplishment by delivering
the results at the end of round 3 it also forced communication across team members
Tools that they learned were great and they were able to see how these are applied in an assembly
environment.
Employees are empowered to brainstorm solutions and make them happen during the exercise
Cross training opportunities during the simulation was performed
CONTACT INFORMATION:
Please contact me for additional information if you wish to learn more about the training.
Luis E. Romero
luroalen@gmail.com
Cell Phone: (619) 519 1173
26412 Crescendo Dr.
Escondido, CA
92026
