Office processes are composed of individual tasks. These processes are generally developed over many years and normally contain steps that are no longer required. A lean office is one where each of these processes has been evaluated and streamlined for maximum efficiency. Wasted movement is eliminated by locating the personnel necessary to perform the task together.

This three-hour office efficiency simulation is divided into four phases. Seven participants are put to work in a fictional company called Widget Works, where they are asked to process quotations. Participants begin with a traditional quotation system, and are gradually introduced to lean principles that streamline the process.

Paper forms are used to simulate completing internal forms or data entry. Faxing and copying are simulated by filling in a brief form at the simulated copy/fax machine. Filing, gaining approvals, and retrieving supplies require the participant to walk around the room simulating normal footsteps in an office process. All of these activities are reviewed as potentially non-value added. The improvements made during the simulation represent changes that can be made to any office procedure. Changes are measured and discussed after each round.

It’s ideal in the boardroom, training center, or the classroom.

Lean Zone® Office quickly teaches your employees concepts such as cellular layout, elimination of non-value added steps, one-piece workflow, pull systems, work balancing, cross training and flexible workforce. They will see why lean office is necessary and desirable. It should help remove their fears and encourage them to identify non-value added activity. The simulation kit includes step-by-step instructions for leading the simulation, along with an 88-slide Microsoft® PowerPoint presentation, plus all the materials needed for seven participants. Everything you need is in one, easy-to-transport package. The complete kit is priced at only $945. We ship internationally!

Lean Zone® Office contains the following tools:

88 Slide Printed PowerPoint Presentation

26 Page Facilitator Manual

39 Laminated Work Instruction Sheets

Quotation Process Forms (enough for 3 simulations)

Excel Metrics Spreadsheet Lean Zone® CD (containing the presentation and metrics spreadsheet)

9 Inbox Trays

2 Paper Clip Holders

1 Horn

13 Pens

1 Reusable Carrying Case

1 Roll of Masking Tape

1 Self-Inking Stamp

Lean Zone® Office applies the same successful principles used in lean manufacturing to the office environment. Participants work in a fictional company where they are introduced to lean practices and experience change as a positive force. In as little as three hours, employees learn concepts such as cellular layout, elimination of non-value added steps, work balancing, cross training and flexible workforce.

Overview:  Most office processes can be completed in one continuous flow.  In many offices, the paperwork moves between different areas of the offices where a different individual adds on the next part of the process.  Office demonstrates how to design a work cell containing all the equipment and personnel necessary to complete the paperwork in one continuous flow.  Once the cell is designed, one-piece flow and work balancing are introduced in increase throughput and eliminate piles of paperwork in in-baskets (work-in-progress).  The simulation also has a final round that shows how to change staffing and work balancing for the process, based on demand changes.

Main teaching points: Cellular Layout, One Piece Flow with a Pull System, Work Balancing (Flexible Work Force), Elimination of Non-Value-Added Steps, Lead Time Reduction, and Rapid Throughput

Other lean concepts: Traditional Office Layout versus Cellular Layout, Standardized Approvals, Point of Use Storage, and Independent Cross Training

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Each Lean Zone® Agile Manufacturing kit includes:

8-page instruction manual

Work instructions

1 deck of airplane cards

30 trays

The complete kit is only $165. We ship internationally!

Lean Zone® Agile Manufacturing is a simulation kit designed for use with Lean Zone® Production Methodologies. It demonstrates the ability of a standardized production facility to produce customer or marketing variations of standard designs with the standard production work cell. Using the current assembly line to produce multiple products saves a large capital investment for the company, and employees realize how relatively small changes can improve plant efficiency.

Overview:  Agile is an add-on to Production Methodologies.  Agile uses the cell developed in Production Methodologies and demonstrates how to manufacture different variations of the product in the same cell.

Main teaching points: Multiple Product Variations Flow through the Same Work Cell.

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The simulation takes place in a fictional helicopter factory where five different sub-assemblies are produced in different areas of the factory. Demand is high but the waste of time, money and non-value-added activities are keeping the factory from meeting customer needs. The simulation shows how to redesign the factory with all five sub-assemblies feeding directly into final assembly with fully synchronized scheduling.  With the help of 7 participants and a little less than 3 hours you and your team can overcome common problems seen in modern factories and brainstorm ideas for your own.

Who can benefit from the Lean Zone Sub-Assembly simulation?

CEO’s/ Business Owners

Supply Chain Coordinators

Operation Managers

Continuous Improvement Managers

Ground Level Employees

The Lean Zone® Sub-Assembly will help your team understand how important synchronized scheduling, cellular design, and visual controls can really be in any work place. The simulation also incorporates quick changeover, one-piece flow, and utilizes quality at the source. These lean tools have been used for many years, but unless your team actually understands them and incorporates them into your organization, you aren’t very lean. The Sub-Assembly simulation can bridge the gap between ideas and reality in your organization.

Overview:  Some products are too large or complex to be fully assembled in one work cell, and multiple sub-assemblies must be assembled in a final step.  Sub-Assembly demonstrates how to re-design the factory where all sub-assembly cells feed directly to final assembly.  Synchronized scheduling and one-piece flow reduce both work-in-progress and lead-time while increasing throughput.

Main teaching points: Traditional Plant Layout versus Lean Plant Layout, Synchronized Scheduling, One Piece Flow with a Pull System, Visual Controls, Lead Time Reduction, and Rapid Throughput

Other lean concepts: Cellular Design, Quick Changeover, Point of Use Storage, and Quality at the Source.

Contents: The kit contains a carrying case, over 2,000 interlocking blocks in four colors and three sizes, over 100 plastic form molded simulation WIP pallets and Raw Material pallets, printed full-scale work station table layouts for each participant area, simulated fixtures used for assembly, laminated work orders, visual signals, facilitator manual, set-up instructions, work instructions for participants, and electronic media with a PowerPoint presentation and Excel metrics spreadsheet.

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Dramatic results reinforce the experience.

Excellent method to break down paradigms.

Lean Zone® Production Methodologies, a cellular manufacturing simulation, has been sold to over 28 countries, and is widely used by Fortune 500 companies and other large organizations, including Bell Helicopter, Price Waterhouse Coopers, Lockheed-Martin, Black & Decker, and Eastman-Kodak as a vital training tool.

Lean Zone® Production Methodologies helps break down employees’ natural resistance to change, making it a practical and entertaining way to introduce new concepts, open constructive dialogue and demonstrate the positive aspects of well-planned directed change. Employees involved in the simulation see why lean Production Methodologies is necessary. It helps to remove their fears regarding change and encourage them to identify non-value added activity. Using a fictional aircraft factory, Lean Zone® Production Methodologies also specifically teaches advanced manufacturing practices, including:

The benefits of cellular manufacturing over traditional plant layouts

The effects of rapid throughput with traditional manufacturing

Work-in-progress as a manageable asset

Inventory risks

Independent cross training

Flexible workforce (load leveling)

One-piece workflow with a pull system

Six participants operate simulated workstations along the assembly line in their imaginary aircraft plant. The four-phase simulation begins with participants producing airplanes using a traditional plant layout. In phases two and three, they redesign their work area into a cellular layout and learn to utilize one-piece workflow with a pull system. In the final phase, they experience the concepts of a flexible workforce and load leveling.

Supplier problems, labor skills, deadlines, quality control and other real-life situations have been incorporated into each phase of the simulation. Each phase lasts six minutes with time for comments and discussion.

Each Lean Zone® Production Methodologies kit includes:

20-page instruction manual

Charts

Feeler gauge

Markers

More than 1000 plastic interlocking parts for constructing airplanes

Many organizations spend hundreds of dollars per person on lengthy seminars for employees to learn what Lean Zone® Production Methodologies can teach in as little as one hour – all for only $765. We ship internationally!

Overview:  Most products can be made in one continuous flow.  In many factories, the different operations that produce the product are spread throughout the factory, and products are moved from one area to the next as they are assembled.  Production Methodologies demonstrates how to design a work cell containing all equipment and personnel required to make the complete part in one continuous flow.  Once the cell is designed, one-piece flow and work balancing are introduced to increase throughput and reduce work-in-progress.

Main teaching points: Cellular Layout, One Piece Flow with a Pull System, Work Balancing (Flexible Work Force), Lead Time Reduction, and Rapid Throughput

Other lean concepts: Traditional Plant Layout versus Cellular Layout, Inventory Risks, Point of Use Storage, and Independent Cross Training

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