Lean Kits and Simulations
Problem Solving Session Including Simulation
This is everything your Lean Facilitator
needs to teach an effective A3 Problem Solving class for your associates.
The session is designed
for 4.5 hours of classroom time learning the problem solving tools
and how to use the A3 template, followed by the 3.5 hour team-based
Problem Solving tools include:
- Root Cause Analysis
- Process Flow Charting
- Value Stream Mapping
- Pareto Chart
- Fishbone Diagram
- Scatter Diagram
- Control Charts & Process Capability
- Error Proofing
simulation kit provides an opportunity for the participants to actually
use the 8 steps of the A3 Process and fill out the included A3 form.
The kit is designed for up to three teams (six associates per team).
The simulation gives the team a chance to demonstrate their A3 Problem
Solving knowledge in a simulated, yet "business-like"
environment, and confirms their understanding of these techniques
through the use of team "report-out" activities. The A3
1. Identify the Problem or Need
2. Understanding the Current Situation/State
3. Goal Statement--Develop the Target State
4. Root Cause Analysis
5. Brainstorm/Determine Countermeasures
6. Countermeasures Implementation Plan
7. Check Results--Confirmation of Effect
8. Update Standard Work
112 PowerPoint slides on a site license CD
- A3 Problem Solving simulation using our standard wood trucks
- A3 template--blank and on CD
- A3 template--filled in per the steps in the PowerPoint slides
and on CD
- 18 laminated problem situation and statement forms
- Implementing World Class Manufacturing book as a reference
for the problem solving tools
Set of Poker Chips for a problem solving exercise
5S is a powerful Lean tool that when implemented will improve safety,
housekeeping, and organiza-tion. 5S reduces business waste by eliminating
searching, hunting, or looking for anything in the administrative
area, office, or the factory.
This is everything your Lean Facilitator needs to teach a powerful
introduction to 5S session for all of your associates. This session
is designed for 6 hours of classroom time (including two videos),
followed by the 2 hour 5S simulation. This simulation includes a
5S audit exercise.
Course Content includes:
-- paving the approach
- Where does 5S apply
5S improves the workplace
- Origin of the 5S's
- Definition and application of: Sort, Straighten/Set In Order,
Sweep/Shine, Schedule/Standardize, Sustain
- Visual controls and production boards
and visual controls in the office A 5S simulation
Upon completion of the 5S Visual Enterprise session, participants
will be able to:
Red Tags to identify unneeded items in their workplaces
5S techniques to layout a work area
visual techniques to speed the flow of information and material
- Link 5S activities to bottom line measurements
- 112 PowerPoint slides on a site license CD
-- 5S Factory Makeover (Society of Manufacturing Engineers)
- DVD -- Introduction to Visual Controls (Society of Manufacturing
- 5S Simulation as described in the PowerPoint slides
audit and scoring sheets -- blank and on the CD
- Book -- Implementing World Class Manufacturing as a reference
for the 5S PowerPoint slides
without the 5S Videos for $541.00
5S Session and Simulation Only
Stream Mapping Kit
everything you need to facilitate successful Value Stream Mapping
events. Kit Contains:
1 Roll of Static Cling Dry Erase Sheets (40 Sheets)
seperately, Item #112SC, $39/Roll)
to draw a neat, clean Value Stream Map almost anywhere and easily
make changes as necessary.
Packages of Process Box Sticky Notes
VSM easier, neater, and more visual. Easily positioned and repositioned,
these (5"x8") notes can be easily read by the entire
team as the map is developed to insure good feedback and participation.
| 1 Package of Cloud Burst Sticky Notes (Available seperately,
Item 112SB, $2.00/Pack of 50)
to denote areas of improvement.
Participant Sheets with Icons
be used by each participant to draw their own value stream map.
Lists the VSM icons for easy reference.
Pack of Multi-Color Dry Erase Markers
Super Sharpie© markers
Roll of Masking Tape
everything you need to run a successful 5S Kaizen Event!
Newspaper Flip Chart Pad: Printed on high quality, glossy
paper for a professional look, our
Kaizen newspaper can be used to visually track Kaizen action items
and their status. 25
Sheets, 27" x 34". (Also available separately,
Item #11261, $39.00)
Event" Vests: Our
"Kaizen Team" event vests are made of a light weight
mesh with a velcro closure. Can be given to participants as a
badge of their participation in a Kaizen event. Package of 12.
Red Tags (200 Tags plus wires)
TPM Action Tags (100 Tags plus wires)
a more organized and efficient Kaizen event!
Kaizen Newspaper Flip Chart Pad: Printed on high quality,
glossy paper for a professional look, our Kaizen newspaper can
be used to visually track Kaizen action items and their status.
25 Sheets, 27" x 34". (Also
available separately, Item #11261, $39.00)
Event" Vests: Use our "Kaizen Team" event
vests to easily identify team members and to let everyone know
that something special is taking place. Vests are made of a light
weight mesh with a velcro closure. Can be given to participants
as a badge of their participation in a Kaizen event. Package of
5S Starter Kit
contains everything you need to start your journey to becoming world
23% off the retail price when ordered as a kit.
(2) 5S Red Tags (Pkg of 100, plus wires)
(1) Putting 5S to Work Book
(1) 5S Pocket Cards (Package of 25)
(2) 2" Yellow/Black Safety Tape
(1) TPM Yellow Tags (Pkg of 100, plus wires)
(1) Implementing World Class Manufacturing Book
(1) Kaizen Vests (Pkg/12)
(1) 5S Red Tag Parking Lot PVC Sign
FREE! World Class Manufacturing Hat (while supplies last)
simulation is designed to show how using Cellular Processing of
the "office information product" substantially reduces
the office information product lead-time (which is one component
of the organization's total customer lead-time) while improving
team work, quality, and productivity.
#1: In a typical organization, everything is departmentalized.
Producing the office information product (for example processing
a new customer order) is completed in a batch/push production
departmentalized environment which creates inventory (wip), motion,
and transportation waste. Team work does not develop since the
departments do not have common goals. There is no cross training
#2: In a cellular office organization, every department that touches
a particular office information product (for example processing
a new customer order) contributes a person to the new cell. Producing
the office information product is completed in a pull production
environment which eliminates/reduces inventory (wip), motion,
and transportation waste. Team work develops now because the team
has a common goal. Cross training is required. Productivity and
Written and video instructions
All materials required to run simulation
takes 1 1/2 hours to complete and requires 11 people to participate.
is a great tool to kick off an office Kaizen Event!"
Matthias, Menasha Packaging Company
had a lot of fun with this activity, and everyone said they got
something out of it!"
Angelo, Grunau Construction Company
Proofing & Problem Solving Simulation
includes simulations for both Error Proofing and Problem Solving.
The kit is designed for up to three teams (six associates per team)
who have been trained in Problem Solving Tools, and should be facilitated
by an experienced Team & Problem Solving Trainer. The Simulation
Kit gives the team a chance to use their Problem Solving Tools and
Error Proofing techniques in a simulated, yet "business-like"
environment, and confirms their understanding of these techniques
through the use of team "report-out" activities.
This simulation kit provides an opportunity to actually use the
- Fishbone Diagram and Multi-voting
- 5 Whys
- Developing an Action Plan
exercise takes approximately 3 hours to complete.
After teams have been trained in Problem Solving, this Error Proofing
Simulation is to be used as part of an Error/Mistake Proofing
class. This exercise teaches the team how to apply the following
Error Proofing techniques:
Design for Manufacturing and Assembly (DFMA)
- Detection in Station
- Successive Checking
exercise takes approximately 1.5 hours to complete.
$169 / Kit
New! 5S Simulation
of Simulation: This simulation is designed to be used as
part of a 5S training class and illustrates the productivity improvements
that 5S activities can produce. Teams also learn how to do a
5S audit, and practice using a "real world" manufacturing
example. The simulatin has two rounds (before and after 5S for an
Assembly Line) and requires 9 people to operate. The simulation takes
approximately 90 minutes to complete. The kit includes instructions
and 15 PowerPoint slides.
Push/Pull Simulation (BOX GAME)
The Flow Simulation (box game) is an enlightening demonstration of the benefits of one-piece flow pull production and the use of processing cells versus traditional push/batch production. It can be used to compare push versus pull production for either “information product” production in the office or “physical product” production in the factory.
The game compares batch or push production techniques to one-piece pull production using processing cells. It shows how teamwork, 5S, quality, and productivity improve with pull production while reducing WIP inventory, rework, product lead-time and the floor space required. It also illustrates how Setup Reduction and Total Productive Maintenance (TPM) are prerequisites for pull production.
The game requires that you set up a 20'x20' production area with four folding tables (or equivalent) and requires 7 people to run the simulation. The simulation assembles a product (6"x3"x3" Styrofoam box) that can be equated to the office processing of an information product. Three different ways to run production are compared (Push 6, Pull 6, and Pull 1). The game takes about 1.75 hours to complete. Includes an instructional video on DVD.
OUR CUSTOMERS ARE SAYING.....
Box Game allowed our entire company to actually experience
the difference between a push vs. a pull production environment.
It sets the stage for your team to start thinking about a
completely different and more effective production process
and the associated benefits that result. Our folks loved it!"
- Jerry Solomon, VP of Manufacturing, MarquipWard United
(Instructional DVD Included)
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