All Lean Zone simulations are designed as hands-on demonstrations. The participants are actively engaged, and visually see the effects of the implemented changes on production. Simulations are designed for use by your training personnel and contain a manual that details how to run the simulation.
Differences Between Simulations
Three Simulations: Two simulations are available for the production environment and one simulation for the office environment. Lean Zone Production Methodologies teaches lean concepts applicable to any production setting. Lean Zone Sub-Assembly demonstrates how a very large facility can be designed with synchronized work cells feeding into a final assembly work cell. Lean Zone Office explains how to redesign an office paperwork process.
Add-On Simulation and Replacement Forms: Lean Zone Agile Manufacturing simulation is an add-on to the Lean Zone Production Methodologies simulation and Lean Zone Office 3 Simulation Form Pack contains a replacement supply of forms for Lean Zone Office.
Concept Comparison Chart:
Lean Zone® Production Methodologies, a cellular manufacturing simulation, has been sold to over 28 countries and is widely used by Fortune 500 companies. This simulation specifically teaches advanced manufacturing practices while helping to introduce new concepts, open constructive dialogue and demonstrate the positive aspects of well-planned directed change.
Overview: Most products can be made in one continuous flow. In many factories, the different operations that produce the product are spread throughout the factory, and products are moved from one area to the next as they are assembled. Production Methodologies demonstrates how to design a work cell containing all equipment and personnel required to make the complete part in one continuous flow. Once the cell is designed, one-piece flow and work balancing are introduced to increase throughput and reduce work-in-progress.
Main teaching points: Cellular Layout, One Piece Flow with a Pull System, Work Balancing (Flexible Work Force), Lead Time Reduction, and Rapid Throughput
Other lean concepts: Traditional Plant Layout versus Cellular Layout, Inventory Risks, Point of Use Storage, and Independent Cross Training
The Lean Zone® Sub-Assembly will help your team understand how important synchronized scheduling, cellular design, and visual controls can really be in any work place. The simulation also incorporates quick changeover, one-piece flow, and utilizes quality at the source. These lean tools have been used for many years, but unless your team actually understands them and incorporates them into your organization, you aren't very lean. The Sub-Assembly simulation can bridge the gap between ideas and reality in your organization.
Overview: Some products are too large or complex to be fully assembled in one work cell, and multiple sub-assemblies must be assembled in a final step. Sub-Assembly demonstrates how to re-design the factory where all sub-assembly cells feed directly to final assembly. Synchronized scheduling and one-piece flow reduce both work-in-progress and lead-time while increasing throughput.
Main teaching points: Traditional Plant Layout versus Lean Plant Layout, Synchronized Scheduling, One Piece Flow with a Pull System, Visual Controls, Lead Time Reduction, and Rapid Throughput
Other lean concepts: Cellular Design, Quick Changeover, Point of Use Storage, and Quality at the Source.
Lean Zone® Office applies the same successful principles used in lean manufacturing to the office environment. Participants work in a fictional company where they are introduced to lean practices and experience change as a positive force. In as little as three hours, employees learn concepts such as cellular layout, elimination of non-value added steps, work balancing, cross training and flexible workforce.
Overview: Most office processes can be completed in one continuous flow. In many offices, the paperwork moves between different areas of the offices where a different individual adds on the next part of the process. Office demonstrates how to design a work cell containing all the equipment and personnel necessary to complete the paperwork in one continuous flow. Once the cell is designed, one-piece flow and work balancing are introduced to increase throughput and eliminate piles of paperwork in in-baskets (work-in-progress). The simulation also has a final round that shows how to change staffing and work balancing for the process, based on demand changes.
Main teaching points: Cellular Layout, One Piece Flow with a Pull System, Work Balancing (Flexible Work Force), Elimination of Non-Value-Added Steps, Lead Time Reduction, and Rapid Throughput
Other lean concepts: Traditional Office Layout versus Cellular Layout, Standardized Approvals, Point of Use Storage, and Independent Cross Training
Lean Zone® Agile Manufacturing is a simulation kit designed for use with Lean Zone® Production Methodologies. It demonstrates the ability of a standardized production facility to produce customer or marketing variations of standard designs with the standard production work cell. Using the current assembly line to produce multiple products saves a large capital investment for the company, and employees realize how relatively small changes can improve plant efficiency.
Overview: Agile is an add-on to Production Methodologies. Agile uses the cell developed in Production Methodologies and demonstrates how to manufacture different variations of the product in the same cell.
Main teaching points: Multiple Product Variations Flow through the Same Work Cell.
The forms are sold as a replenishment to the main kit itself. With the purchase of the Lean Zone Office kit you will receive a form pack, the work instructions, and other accessories required to perform the simulation. Once you have run out of the provided forms and paperwork, you may purchase a replenishment pack.