How does Lean Zone compare to other training approaches?
When planning lean training, you're not just choosing a product — you're choosing an approach. Here's how the options compare.
| Criterion | External Consultant | Multi-Day Seminar | E-Learning / Video | DIY Simulation | Lean Zone® Kit |
|---|---|---|---|---|---|
| Cost per person (1st session) | $200–$600+ | $300–$500+ | $50–$150 | $50–$200 + design time | $96–$128 |
| Cost per person (10th reuse) | Same | Same | Same | Materials only | Under $10 |
| Time investment | 1–2 full days | 2–5 days | Self-paced (hours) | Weeks to design | 1–1.5 hours |
| Participant engagement | Variable | Moderate | Low (passive) | Variable | Very high (hands-on) |
| Facilitator required? | External (recurring $) | External | No | Internal (heavy prep) | Internal (20 min prep) |
| Reusable? | No (per visit) | No (per person) | Yes | Yes | Unlimited |
| Concepts per session | Broad | Deep but time-heavy | Narrow | Depends on design | 7+ lean concepts |
| Proven at scale? | Varies | Varies | Varies | Untested | 48+ Fortune 500 cos. |
The key differences
The upfront investment ($765–$995) is higher than a single e-learning license, but the kit is reusable indefinitely. By the tenth session, you're training people for under $10 per participant.
A full simulation with discussion runs 60–90 minutes compared to 1–5 days for traditional approaches. This matters in manufacturing and operations where pulling people from the floor for extended training is costly.
Every kit includes a facilitator manual that allows any internal trainer, lean champion, or manager to run the session after about 20 minutes of preparation. No scheduling consultants, no recurring fees.
People remember approximately 10% of what they hear in a lecture but up to 75% of what they learn through practice. Lean Zone participants physically build products, reorganize workstations, and experience improvement firsthand.
"It is engaging, educational, fun and leaves a positive memorable impression with the participants at all levels of the organization! The game is easy for the facilitator to run, and easy for the students to grasp."— Mike Osterling, President, Osterling Consulting (200+ facilitations over 18 years)
Three kits for different environments
Production Methodologies
$765
Airplane factory simulation. Best for introducing lean to any audience. Teaches cellular manufacturing, one-piece flow, pull systems, and work balancing. 6-8 participants, 1-1.5 hours.
View KitLean Office
$945
Quotation process simulation. Best for office and administrative environments with paperwork and approvals. 7 participants, 3 hours.
View KitSub-Assembly
$995
Helicopter factory simulation. Best for complex multi-station manufacturing with scheduling challenges. 7 participants, 2.5-3 hours.
View KitNot sure which kit is right?
Download our free Buyer's Guide for a detailed comparison, ROI worksheet, and evaluation criteria to help you decide.
Download the Free Buyer's Guideor call 817-509-0680 to talk it through