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Lean Supermarket

Lean Factory Flow Kit


Lean Factory Flow Kit


Product Description

Great lean simulation training package. This training exercise takes about 90 minutes from start to finish. The training progresses from batch, to smaller batches, and then to single unit flow in 3 rounds of simulation. Metrics are tracked at each stage of the process and participants will see the dramatic effect of single unit flow verses traditional batch manufacturing.

This is a great training exercise to for all employees. It will give your entire team a basic understanding of many lean principles and the financial impact that lean could have on your organization. This training exercise will be critical to getting more employees on board with your lean efforts. 

During the training, measurements of lead-time, quality, production, work-in-process inventory, number of changeovers, and profitability are taken through each of the three simulations.  Kit for 8 to 10 participants.

Breakdown of 90 minutes of training:

1st simulation = Traditional manufacturing process or batch production

·        Participants are in isolated departments and material is moved from department to department.

·        All work is routed though the quality inspector.

2nd simulation = Batch sizes are cut in half while still in traditional manufacturing setup

·        This highlights that smaller batch sizes actually promote faster throughput without negatively affecting output.

3rd simulation = Batch size of 1 unit.

·        Employees learn the concept of pull from person to person.

·        They are also encouraged to change the manufacturing layout to best promote flow.

Included in Lean Factory Flow Kit:

  • 80 - Flashlights and components
  • 160 - Batteries
  • 1 - Facilitator Guide with Presentation CD
  • 1 - Container for flashlight bodies
  • 1 - Container for flashlight parts


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