Folsom, CA 95630
916.353.1243

Home Contact Us Client List Lean Case Studies Lean Enterprise Lean Simulation Kits Product Flow Set-up Reduction Training Visual Controls VSM About Us

Home
Contact Us
Client List
Lean Case Studies
Lean Enterprise
Lean Simulation Kits
Product Flow
Set-up Reduction
Training
Visual Controls
VSM
About Us

Lean Simulation Kits

TEiM staff has plenty "hands-on" experience about how to deliver training seminars and how lean can be implemented. Based on this experience over the years TEiM has developed three lean simulations to demonstrate how any company can transition from a traditional manufacturing organization into a lean enterprise. 

The advantage of using a simulation is that any company can easily train its key people about how to implement lean principles in a classroom environment without having to interfere with the manufacturing floor. The simulation process also dramatically shortens the learning curve of most organizations over those who use a "lets try it ourselves and see" method. An organization with no prior lean implementation experience will take from 3 to 5 years to achieve a acceptable level of improvement. In fact there are many stories of companies who embark on a lean program only to shelve it because it did not deliver acceptable results in process improvement or the bottom line for use of internal resources.

The purpose of a simulation is to allow people to learn through play, because this gives them the ability to totally engage in the process without the fear of failure. The three TEiM simulations available for purchase are:

Level 1 - Introduction to Lean Manufacturing.

Level 2 - Implementing Lean Manufacturing.

Level 3 - Lean Culture and Change. ( On-site presentation by TEiM  using level 2 kit )


Level 1    Introduction to Lean Manufacturing:

TEiM developed this basic kit to demonstrate lean concepts to organizations who have little or no knowledge of lean manufacturing. The Level 1 kit takes the group through a simple production line simulation using Lego™ to manufacture a finished product. As the group are taken through 4 levels of improvement they learn how to develop a team approach when identifying and implementing improvements, and see first hand how their decisions will effect the whole manufacturing process from procurement of raw materials to shipping the finished product to the customer. Total time required for the simulation is approximately 1 hour and requires a minimum of 7 people in attendance to successfully run the simulation.

The kit consists of:

  1. A training CD which includes; training manual, process paperwork and assembly drawings and a profit and loss spreadsheet.

  2. A Lego™ kit.

  3. Tool box which includes; stop watches, measuring equipment, clip board, pens and note pad.

  4. Rolling tote bag with pull handle to hold all items for easy storage and transportation.

Level 1 kit price is $950 plus shipping & handling.

To order a Level 1 kit please call David Jones at 916-353-1243 (between 8:00 am to 6:00 pm PST)


Level 2    Implementing Lean Manufacturing.

TEiM developed this kit to demonstrate how to implement lean principles into an organization that has some internal knowledge of lean manufacturing. 

This kit uses a mixed model production line simulation using Lego™ to manufacture a finished product. The purpose of this mixed model process is to show more realistically a typical manufacturing environment. Many companies don't have the ability to create dedicated product cells because of resource constraints , so they must put several products through the same line or cell. The kit also introduces the group to the process of dealing with both standard and/or custom orders produced in the same line or cell.. The group learn how to develop a team approach to identifying and implementing improvements, and how their decisions can effect the whole manufacturing process from the procurement of raw materials to shipping the finished products to the customer. Total time required for the simulation is approximately 2 hours and a minimum of 12 people in attendance to successfully run the simulation.

The kit consists of:

  1. A Level 2 training CD which includes: training manual, process paperwork and assembly drawings, simulation documents, customer order and receiving forms, order entry forms and a profit and loss spreadsheet. Also included with this package is the Level 1 training CD - "Introduction to Lean."

  2. A multi color Lego™ kit.

  3. Tool box which includes; stop watches, measuring equipment, clip board, pens and note pad.

  4. Rolling tote bag with pull handle to hold all items for easy storage and transportation.

Level 2 kit price is $1,800 plus shipping & handling.

To order a Level 2 kit please call David Jones at 916-353-1243 (between 8:00 am to 6:00 pm PST)

To include a one day training session to show trainers how to use the Level 2 kit, the total price is $3,650 plus additional expenses.

Any additional expenses incurred as a result of a training session being more than 4 hours driving time from Sacramento, CA (i.e. air travel, overnight accommodation, etc.) will be added to the Level 2 kit price..


Level 3    Lean Culture and Change

This training experience is primarily designed to help management better recognize and deal with the issues employees will face as the company moves to become a Lean Enterprise.  Designed for Managers, Senior Managers and Business Directors/Owners this training utilizes the level 2 Lean simulation kit to raise the awareness of both the tools of lean such as Kan-ban, Batch reduction and Layout and also the cultural and/or staffing reaction to change created by the move to Lean.  Built into the training are examples of change brought about by the move to Lean and how staff may/will react if the thoughtful Lean implementation does not occur.  In addition to the usual Level 2 simulation participants we have added an HR department, a staff safety/non-conformance element, a traditional staff incentive program and additional Non-value added paperwork activities.  We also cover elements of Leader Standard work and the necessity for that to occur to sustain Lean.  A discussion about traditional organizational structures compared to the Lean Servant Leader relationship is also covered.

Level 3 On site training price is $3,900

To order Level 3 training please call David Jones at 916-353-1243 (between 8:00 am to 6:00 pm PST)

Any additional expenses incurred as a result of a training session being more than 4 hours driving time from Sacramento, CA (i.e. air travel, overnight accommodation, etc.) will be added to the Level 3 On site training price.

 

The picture below shows participants of a TEiM run Level 2 Simulation in progress.  The hands on nature make people think and remember the Lean concepts, while having fun

 


 
Lean simulation kits can save lots of time by shortening learning curves?
People enjoy learning in a fun atmosphere. If the training process is interactive and fun they retain the information longer than using any other method.

In addition to having fun its important to use a method that shortens the learning curve. Using a simulation facilitates this process.


Satisfied Customer Quotes

"We just completed our summer training of 400 people. Nearly all employees said the lego class was the best training they have ever received in their Syngenta lifetime".

Cheers,
 
Kelly Moore
Syngenta Crop Protection Inc

 

"I wish we had done the level 3 training before we started our implementation. We would have made much better progress and understood what to expect"

 

Lisa Lyon PSS World Med  

 

 

Copyright © 2010 Total Excellence in Manufacturing Inc. | Home | Site Map | Contact Us