TEiM staff has plenty "hands-on" experience about how to deliver training seminars and how lean can be implemented. Based on this experience over the years TEiM has developed three lean simulations to demonstrate how any company can transition from a traditional manufacturing organization into a lean enterprise. 

The advantage of using a simulation is that any company can easily train its key people about how to implement lean principles in a classroom environment without having to interfere with the manufacturing floor. The simulation process also dramatically shortens the learning curve of most organizations over those who use a "lets try it ourselves and see" method. An organization with no prior lean implementation experience will take from 3 to 5 years to achieve a acceptable level of improvement. In fact there are many stories of companies who embark on a lean program only to shelve it because it did not deliver acceptable results in process improvement or the bottom line for use of internal resources.

The purpose of a simulation is to allow people to learn through play, because this gives them the ability to totally engage in the process without the fear of failure. The three TEiM simulations available for purchase are:

Level 1 - Introduction to Lean Manufacturing.

Level 2 - Implementing Lean Manufacturing.

Level 3 - Lean Supply Chain

Level 1    Introduction to Lean Manufacturing:

TEiM developed this basic kit to demonstrate lean concepts to organizations who have little or no knowledge of lean manufacturing. The Level 1 kit takes the group through a simple production line simulation using Lego™ to manufacture a finished product. As the group are taken through 4 levels of improvement they learn how to develop a team approach when identifying and implementing improvements, and see first hand how their decisions will effect the whole manufacturing process from procurement of raw materials to shipping the finished product to the customer. Total time required for the simulation is approximately 1 hour and requires a minimum of 7 people in attendance to successfully run the simulation.

The kit consists of:

1. A training CD which includes; training manual, process paperwork and assembly drawings and a profit and loss spreadsheet.

2. A Lego™ kit.

3. Tool box which includes; stop watches, measuring equipment, clip board, pens and note pad.

4. Rolling tote bag with pull handle to hold all items for easy storage and transportation.

Level 1 kit price is $950 plus shipping & handling.

To order a Level 1 kit please call David Jones at 916-353-1243 (between 8:00 am to 6:00 pm PST)

Level 2    Implementing Lean Manufacturing.

TEiM developed this kit to demonstrate how to implement lean principles into an organization that has some internal knowledge of lean manufacturing. 

This kit uses a mixed model production line simulation using Lego™ to manufacture a finished product. The purpose of this mixed model process is to show more realistically a typical manufacturing environment. Many companies don't have the ability to create dedicated product cells because of resource constraints , so they must put several products through the same line or cell. The kit also introduces the group to the process of dealing with both standard and/or custom orders produced in the same line or cell.. The group learn how to develop a team approach to identifying and implementing improvements, and how their decisions can effect the whole manufacturing process from the procurement of raw materials to shipping the finished products to the customer. Total time required for the simulation is approximately 2 hours and a minimum of 12 people in attendance to successfully run the simulation.

The kit consists of:

1. A Level 2 training CD which includes: training manual, process paperwork and assembly drawings, simulation documents, customer order and receiving forms, order entry forms and a profit and loss spreadsheet. Also included with this package is the Level 1 training CD - "Introduction to Lean."

2. A multi color Lego™ kit.

3. Tool box which includes; stop watches, measuring equipment, clip board, pens and note pad.

4. Rolling tote bag with pull handle to hold all items for easy storage and transportation.

Level 2 kit price is $1,800 plus shipping & handling.

To order a Level 2 kit please call David Jones at 916-353-1243 (between 8:00 am to 6:00 pm PST)

To include a one day training session to show trainers how to use the Level 2 kit, the total price is $3,650 plus additional expenses.

Any additional expenses incurred as a result of a training session being more than 4 hours driving time from Sacramento, CA (i.e. air travel, overnight accommodation, etc.) will be added to the Level 2 kit price..

Level 3    Lean Supply Chain

TEiM developed this kit to demonstrate some of the key issues that can be experienced particularly after a lean implementation. A key realization by every organization is that by implementing lean they have dramatically improved their internal capabilities to meet the demands of their customers. However, many organizations just don't see a significant increase in output even thought their lean metrics do indicate an improvement in productivity. Why is this? 

A key reason is that once an organization has implemented lean internally, it can only improve on it's delivery performance to it's customers at the same rate that it's suppliers are capable of delivering materials to them. Therefore, the next focus of a lean program after the initial implementation must be to move externally to do an assessment of all key suppliers. This will determine if your current suppliers have the capability of supporting your operation today and the future growth of your business. The Level 3 kit introduces the audience to a live simulation to demonstrate how the supply chain can determine the success or failure of any lean implementation.

The Level 3 kit allows you to take the group through a supply chain simulation. They will operate as a fictitious company that is ordering Lego™ blocks from three suppliers and one sub-assembly from a single vendor using all the standard documentation required to manufacture multiple finished products. The purpose of using the mixed model simulation is to show how the process was improved during the lean implementation which allowed the company to put several products through the same production line and to demonstrate how output is effected by supply chain problems. The simulation is run three times and the group will experience three levels of improvement, which clearly demonstrates how the relationship between demand and supply determines on time or late delivery to the customer. 

The group will learn how good communication is the key to identify problems and implementing improvements to the material re-order process to meet customer demand. The group will also experience first hand, what effect their decisions have on the whole manufacturing process from the procurement of raw materials to shipping the finished product to the customer. Total time required for the simulation approximately 2 hours and a minimum of 20 people in attendance to successfully run the simulation.

The kit consists of:

1. A Level 3 training CD which includes: training manual, supply chain instructions and assembly drawings, customer order and receiving documentation, order entry, material procurement documentation, supplier documentation and a profit and loss spreadsheet. Also included with this package is the Level 1 training CD - "Introduction to Lean" and Level 2 training CD - "Implementing Lean."

2. A multi color Lego™ kit.

3. Tool box which includes; stop watches, measuring equipment, clip board, pens and note pad.

4. Rolling tote bag with pull handle to hold all items for easy storage and transportation.

Level 3 kit price is $3000 plus shipping & handling.

To order a Level 3 kit please call David Jones at 916-353-1243 (between 8:00 am to 6:00 pm PST)

To include a one day training session to show trainers how to use the Level 3 kit, the total price is $5,450 plus additional expenses.

Any additional expenses incurred as a result of a training session being more than 4 hours driving time from Sacramento, CA (i.e. air travel, overnight accommodation, etc.) will be added to the Level 3 kit price.