Lean Simulator Guide

Everything you need to run Lean Simulator, and the Lean ideas behind it. Follow the six-shift journey from push and batch to takt time.

Getting started

• What is Lean Simulator?: what it is, how it works and who it is for
• Try a free shift: one shift on the line, free, with Evan guiding you
• How to join a Lean Simulator game: joining a game with a five-digit code
• How to host a Lean Simulator game: opening a game and running a session
• Roles on the line: what each role on the line does
• Meet Evan, the built-in facilitator: the built-in facilitator and how to work with him

Running a workshop

• How to run a Lean simulation workshop: group size, timings, debriefs and sample agendas
• Session plans for a Lean simulation workshop: 75-minute, half-day and full-day plans
• How to debrief a Lean simulation: a four-step debrief and questions for each shift
• Reading the results: WIP, lead time and profit: work in progress, lead time, floor space and profit

The six-shift journey

• The six-shift journey: the whole journey on one page
• Shift 0: the induction: the no-clock practice floor
• Shift 1: Push and Batch: the wasteful starting point
• Shift 2: Layout and Flow: stations in process order
• Shift 3: Pull with Kanban: kanban and pull
• Shift 4: One-Piece Flow and Quality at Source: batch of one, no inspector
• Shift 5: Balance the Line: removing the bottleneck
• Shift 6: Takt and Levelled Scheduling: matching the pace to demand