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Welcome to Lean Games

Lean games provides complete, ready to use simulations and business training games for use in training and implementation of lean manufacturing, lean office and continuous improvement techniques. They are intended for use by consultants, in house company trainers and academics 

 

SMED Lean Simulation

SMED Lean Simulation

The SMED Lean Simulation

Based on a simulated machine it can be used to teach Lean manufacturing across a wide range of industries for example, CNC machining, packaging, food, plastics, electronics, printing, etc. The machine simulates mechanical, pneumatic, colour and software alterations and also the manufacture of a "first off" with quality inspection. The aim of the training is to demonstrate the principles of SMED and allow the trainees to practice the SMED methodology on this simulation before starting actual implementation on their own equipment.

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Normally the game involves 2 volunteers who changeover the machine using the standard procedure supplied and a little guidance from the facilitator. It would be quite possible for up to 20 other people to observe the changeover, although normally we would expect a group of between 6 and 12 participants. All the participants then work through each of the steps of SMED, applying them to the original procedure, this is normally done in smaller sub groups of 2 or 3 people. The SMED training simulation normally takes half a day to run.

Each kit is supplied in its own easy to store and transport bag and contains the following:

- The simulation machine (approximate dimensions (500mm x 500mm)
- Instructions on how to run the simulation
- Required changeparts
-All necessary spanners/tools
- Standard quality samples
- USB cable to simulate software download - it is assumed you would use your own laptop to demonstrate this with the trainees
- Standard operating procedure for the traditional changeover
-Suggested ideas to achieve a single minutes changeover and some additional parts to demonstrate the practice
- Stop watch to carry out the timing

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The price of this game is £845.00 (exc. VAT)

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Plug Game Simulation

Plug Game Simulation

The Plug Game 

The Plug Game is a manufacturing simulation based on assembling 3 pin plugs, it is ideal for business process improvement training to demonstrate the following concepts:

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- Layout
- Push/pull
- One piece flow
- Kanban
- Work balance
- Benefits of training

Our lean simulations are complete, ready to run games containing:

- Dismantled plugs, screwdrivers for assembly, stopwatches for timing
- Instruction booklet and CD with PowerPoint standard operating procedures and Excel measurement table
- Standard operating procedures with colour photos
- Objectives

Number of participants:
- Each lean manufacturing simulation can be run with 6 to 12 people
- Additional people can be observers

Running the Plug Game
- This is normally run over 4 rounds of 10 minutes with discussion on learning and improvements made between each round The whole game normally takes 2 -3 hours to complete Each lean simulation can be used many times over

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The price of this game is £325.00 (exc. VAT)

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Six Sigma Game

Six Sigma Game

The Catapult Six Sigma game

This is an ideal practical training simulation to demonstrate the application of problem solving techniques such as fishbone diagrams, brainstorming and six sigma / DOE. It is used as the basis of exercises to understand the process, control variation and deliver improved performance.

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The catapult is designed to "shoot" a lightweight ping pong size ball at a target which is typically placed 3 - 4 metres (10 - 14 feet) away. There are a number of settings and variables designed into the catapult which need to be understood and controlled to make each shot repeatable and accurate.

The catapult game can take between 1 hour and 8 hours to run depending on the depth of learning required.

The game is normally run with a small team of between 4 - 6 people. For larger groups further catapults can be used.

A PDF instruction manual (184 pages) is included, which in summary covers:

  1. An introduction and overview of the catapult
  2. A range of experiments/ exercises that can be carried out
  3. Measurement systems
  4. Design of experiments
  5. Standard operating procedures and key variables to be controlled

The catapult is supplied in its own easy to store and transport bag and contains:

  1. Transport/storage bag
  2. Catapult
  3. Tape measure
  4. Set of balls
  5. PDF Instructions

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The price of this game is £325.00 (exc. VAT)

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Torch Game Simulation

Torch Game Simulation

The Torch Game 

 

The Torch Game is a manufacturing simulation based around assembling torches, with larger components it requires less dexterity than the plug game. A number of components have been modified to cause defects during assembly, therefore the simulation is ideal for reinforcing the importance of quality improvement. In addition to the concepts demonstrated by the plug game we recommend the torch game for the following:

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- Quality filter mapping
- Recording data
- Understanding customer requirements
- Pareto analysis

Our lean simulations are complete, ready to run games containing:

- Dismantled torches in two colours, some faulted, AA batteries and stopwatches
- Instruction booklet and CD with PowerPoint standard operating procedures and Excel measurement table
- Standard operating procedures with colour photos
- Objectives

Number of participants
- Each lean simulation can be run with 6 to 12 people
- Additional people can be observers

Running the Torch Game
- This is normally run over 4 rounds of 10 minutes with discussion on learning and improvements made between each round
- The whole game normally takes 2 -3 hours to complete
- Each lean simulation can be used many times over

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The price of this game is £325.00 (exc. VAT)

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Lean Office Game

Lean Office Game

The Lean Office game

This business training game is an experiential learning simulation based around processing customer orders for computer equipment. Participants in the Lean Office game are asked to take on various roles. The game includes sales, customer liaison, finance, transport/logistics, operations, warehouse and supervision. The objective of the game is to highlight typical inefficiencies that are found in modern office work environments and demonstrate how simple changes can be implemented to improve effectiveness and customer satisfaction. The participants are challenged to correctly complete data on invoices and order acknowledgement forms. The game aims to cover the following key areas:

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  1. Multiple signatures in getting purchase/order no's
  2. Batch & queue of information
  3. Personal filing systems
  4. Multiple sign-off's and delays they cause
  5. Reports that nobody reads
  6. Poor office layout and excessive walking
  7. Unpredictable lead-times
  8. Out of date reports
  9. Lost data and sales opportunities
  10. Data input errors
  11. Lack of skills and training
  12. Artificial demand and rework
  13. Waste of customers time
  14. Delivering what the customer does not want
  15. Wrong/misaligned targets

The Lean Office game takes about 3 hours to run and following a first round, the existing process is mapped and improvements agreed and developed by the team before re-running the game with the new improved processes.

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The price of this game is £300.00 (exc. VAT)

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5S Game

5S Game

The 5S Challenge Game

This is a hands on simulation which is ideal for use as a practical business training game for participants to understand and apply the principles of 5S. The game has successfully been used in both service and manufacturing environments.

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We are also able to offer the game in a 5C and 6S versions.

The principle of the game is based around a “puzzle” involving the assembly of a set of 10 mm thick aluminium parts to form the letters 5 and S. The complete 5S game consists of two separate boxes of parts.

Organised box – This box is presented in an organised layout with each part contained in foam cut outs, this box also includes colour step by step assembly instructions.

Dis-organised box – This box of parts is not well organised, all the parts needed are jumbled up with non-conforming parts and un-necessary items. In addition the assembly instructions with this box are vague.

The game is run over several rounds.

In the first round two teams of two people are selected from the trainees. Each team is given one of the boxes. The teams start the task together and are timed. The team with the organised box of parts will typically complete the task within 2-4 minutes; however the team with the dis-organised box of parts will take much longer and in some cases decide that the task is impossible!

Following a review of this activity the whole group are facilitated in applying the principles of 5S to the dis-organised box. Sorting out the components (including red tagging), setting locations, agreeing standards and future audits etc. Once the participants have completed their 5S activity the teams are re-timed to complete the assembly task using both boxes in a head to head challenge. This time however, the team with the box which has been "5S'd" during the training workshop will almost certainly complete assembly much quicker than the team with the organised foam cut out box thus highlighting the benefits of improved workplace organisation, ownership and continuous improvement.

The 5S challenge game can take anywhere between 45 minutes to 3 hours to run, allowing for discussion, depending on the depth of learning required.

The 5S challenge game comes with full step by step instructions, some red tags, and a stopwatch and can be run time and time again. If you are working with larger groups, additional dis-organised boxes are available at £85 + vat. The standard game is ideal for demonstration or training with a group and is normally run with 4 participants, with up to 20 observers. However if you would like all trainees to experience the hands on activity we would recommend one additional disorganised box for every 3 trainees.

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The price of this game is £195.00 (exc. VAT)

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5S Disorganised Set

5S Disorganised Set

If you are working with larger groups, additional dis-organised boxes are available at £85 + vat. The full standard 5S Game is ideal for demonstration or training with a group and is normally run with 4 participants, with up to 20 observers. However if you would like all trainees to experience the hands on activity we would recommend one additional disorganised box for every 3 trainees.

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The price of this game is £85.00 (exc. VAT)

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