The Value of Lean Simulations
The value of lean simulations is well known and what they provide to not only the people directly involved, but all the others those people work with every day and share with their knowledge and experience is very positive.
What are lean simulations? They are structured activities that mimic real-world scenarios to help teams develop new skills, practice real-world scenarios, and solve problems. Over the years, as technology has advanced, remote work expanded and in-person training decreased, virtual or hybrid models of lean simulations have emerged to play a larger role.
The benefit of virtual or hybrid lean simulations is being able to include and thus reach more people in real time with only minimal technology required. The downside is not everyone is in the same room working together to solve problems or brainstorm ideas. That can still happen in a virtual or hybrid simulation, but it is harder to consistently generate that dynamic.
Virtual Simulations
In a fully virtual simulation, all participants connect to the training remotely using a video conferencing platform. The entire interaction, from discussions to team building games to exercises, happens in a digital space. This format is ideal for teams spread across different buildings or regions.
As stated above, the challenge with virtual lean simulations has been bringing the energy, chemistry and functionality of an in-person session. After the global COVID-19 pandemic pushed industrial organizations to embrace this opportunity, the virtual option is here to stay and can definitely be effective in the right situations.
Hybrid Simulations
A good compromise option to benefit from both the energy and knowledge sharing of an in-person lean simulation and the ability to bring a bigger group together from different locations is the hybrid simulation option.
In a hybrid set up, some participants are present in a room with other people joining via remote video conference or sometimes on a phone call. Hybrid lean simulations offer the opportunity to have groups of people from different companies going through the simulations. By achieving a critical mass of people who are at a similar stage in their Lean/OpEx journey, the sharing of knowledge and learning can help all gain the skills they need.
An example of a lean simulation is Prosit’s Lego 101 process. This simulation is an exact model of how Prosit works with clients to implement and leverage the power of a customized continuous improvement process. Takt time, cycle time, number of parts through and responding to different demand levels are just some of the aspects touched on in the simulation.
The lean manufacturing simulation is presented in multiple phases to highlight how repetitive practice teaches people to identify and resolve problems, sharpen their skills and apply the lean manufacturing concepts, 5S, Kanban and Kaizen, as a team and individuals.
It is always rewarding to see people move from confusion and frustration to confidence and satisfaction as they understand the value of the process and integrate it naturally into their daily work flow. There are also targeted training sessions in between the phases to reinforce the lessons learned.
View our Lego 101 video for details (see below) or contact us to schedule a lean assessment or lean consulting session to help your organization.