Introduction to Lean Games

First of all, what is this project about, and what do we mean here by simulation games?

For a while we are concentrating on lean related games physically played by people in a simulated environment (i.e. not in the workplace, but usually in a classroom).

Depending on the available time and other resources, various approaches can be used to train people using simulation games.

In the simplest and quickest form trainees get a quick briefing about the methods to be practised. That is followed by a – usually simple – game, when trainees can apply the previously learned knowledge in a simulated environment. Quite often this approach is used, when operators are trained for using a lean tool to be introduced at the workplace.

A more advanced and more motivating way of learning is when the participants can make decisions, such as how to conduct work, or even how to change the work environment and production rules. For example they can decide to set up a cell or to use pull signals (perhaps even size kanbans). This approach needs more time and more experienced trainers. However, it is potentially much more useful in deepening knowledge and to prepare the trainees to participate in lean workshops in the real world.

The most advanced, and most challenging way of gaming (for trainees and trainers alike) is when participants are expected to “discover” lean principles and tools under the guidance of a very experienced facilitator.

A wide range of materials are used during lean simulation games. One approach is to use purpose made parts and elements, such as wooden model cars or readymade commercial products, such as flashlights. Others are using LEGO or Duplo blocks. Another approach is to use simple materials available in any stationery shop, and which can be found in most offices anyway. We prefer the last approach.

Some advantages:

  • inexpensive
  • no need to wait for delivery
  • if something is lost or broken, it is easy to make up for the shortage
  • no problem, if more than one group want to play
  • no need to worry about shortages, in case you want to modify the game
  • no time is lost due to disassembly
  • complex situations can be simulated, which include processing, not only assembly

Even with such simple materials, it is possible to play sophisticated games and to teach various lean methods, including (but not limited to):

  • 7 wastes (muda) elimination
  • CONWIP
  • heijunka
  • JIT
  • kanban
  • line balancing
  • manufacturing cells
  • mixed model production
  • one piece flow
  • pull production
  • sequential pull
  • standard work
  • VSM
  • waterspider (mizusumashi)

We are in favour of playing short games, so that enough time is left for preparations and evaluations to complete the learning cycle.

It is particularly challenging (but not impossible) to play lean games in a way that those mirror the running of a workshop of a real company. An advantage of this approach is that quite realistic cash flow and profit calculations can be performed.

If you are interested in our version of the paper airplane game, click here.