This game is broken down into 4 different competition heats.  The challenge is to deliver 12 sets of assembled widgets to the customer in the shortest time and with the least amount of finished inventory (Raw, WIP, and FG).  The first heat is a base line run with a production batch of 6 widgets.  In each heat (run), the time of the first delivery to the customer is recorded as well as the total production time and the finished inventory.  The factory will continue to produce ( show overproduction) until the customer recieves the first delivery (batch) complete.  The team is instructed to appy 5s to organize parts.  The subsequent runs are in batches of 3, 2, and finally a 1 piece flow.  The students can see a very significant (exponential) reduction of production cycle time when the batch sizes are gradually reduced.  Also the customer receives his products much sooner leading to faster cash flow and customer satisfaction.  The total inventory is also reduced due to the elimination of overproduction and total unused inventory.  This scenario is foreign to the normal way Industrial Engineers calculate time value using a linear production method.  It completely changes the misconcept that running large batches is more effective because there is no need of frequent changeovers.  This exercise is especially an eye opener to the business (transactional) employees, because more business processes are structured to work in large batch sizes (by days, or by weeks).  This game also touches briefly on a balance work flow and cellular manufacturing.  

Learning Features:

Demonstrate the power of simple 5s organization

It Stresses the evil of time wasted by waiting especially in office process

Demonstrate interaction of Takt time and Cycle time by time observations

Show the impacts of imbalance work flow caused by design...not people

Show incremental gains in productivity by gradual batch size reductions

Show batch sizes can significantly affect time to market

Introduction to cellular manufacturing and Kanban replenishment

Demonstrate the power of flexible and agile manufacturing

Show how batch sizes can affect cash flow.

Pricing & Availability:

Basic kit (12 Widgets with carrying case) -  USD $ 200 (1 week delivery)

Deluxe kit (24 Widgers with carrying case ) - USD $300 ( 2 week delivery)

Additional warehouse, trucks & forklifts - call for quote.

Group sizes & duration:

Best for 5 people team with 3 to 5 teams together.

Generally last from 60 minutes to 2 hours.

Suitable for all management levels from shop floor to C-level management.

Great for finance, mfg, and supply chain

Transforming a traditional business into a Lean Enterprise requires stakeholders that understand and embrace the SQDC discipline and execution.  This simulation game is used during a week long Lean or Six Sigma training class.  At the end of each day, the instructor would ask the students (in groups) to apply the daily learning and continue to improve their respective factory design and manufacturing methodology.  The students find out quickly that without quality, speed is meaningless.  The class must develop a flexible manufacturing structure to win the team competition on the final day.  The customer can change his order quantity and mix styles anytime.  This game really brings the Lean and Six Sigma tools seamlessly together.  The competition is intense and challenging till the very end.  

Learning Features:

Quality & Quantity are inseparable.

Poke Yoke is more effective than 100% inspection

Simplcity is better than elegance

Make it a visual factory

Takt time vs Cycle time

Test and Validate constantly

Always consult with the customer (CTQ)

Flawless exectuion comes with practice

Pricing & Availability:

Deluxe kit (for 4 teams) -  USD $ 250 (2 week delivery)

Group sizes & duration:

Best for 5 people team with 3 to 5 teams together.

Generally last from 30 minutes to an hour for each run at each of each day.

Best for a week long Lean Sigma training class

Suitable for all management levels from shop floor to C-level