This simulation takes a look at the difficulties of complex products that are unable to be produced in just one area of a factory. Many times, there is miscommunication between separate workstations and final assembly; leading to incorrect or defective parts causing an increase in scrap and WIP (Work in Progress).
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.
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.
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.
7 participants per kit
30lbs / 26" x 16" x 14"
14kg / 66cm x 40cm x 36cm
What you will need:
A room at least large enough to hold two 36” x 72” tables with one smaller table along the exterior wall and seven chairs. You can adapt the simulation to almost any room and table configuration.
Tables in one of the following configurations: one 4’x12’ table, two 4’x6’ tables, or four 30”x6’ tables. In addition, you will need a small table minimum 18”x3’.
Each Lean Zone® Sub-Assembly kit includes:
- A carrying case
- 2,000+ interlocking blocks in four colors and three sizes
- 100+ plastic form 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
- Electronic media with a PowerPoint presentation and Excel metrics spreadsheet