2-Day Lean Simulation Bootcamp
Seats are limited! Bring your team and delve into the key methods of lean.
Dallas-Fort Worth, TX
$1,850 per person
Participants work as a team in a production simulation to understand the impact of process improvements by applying fundamental lean methods such as Toyota Kata, 5S, 7 Wastes, Flow, and Pull.
Participants reflect on gains by tracking their improvements through process metrics and P&L statements.
This is a 2-Day, in-person workshop located at the Gemba Academy training facility centrally located in the Dallas-Fort Worth area in Keller, TX.
Who is this for?
- Frontline, CI and Operations professionals at all levels.
Why Should I Attend?
- Eliminate pain points and friction
- Increase velocity
- Increase profits
- Boost employee engagement while experiencing the fundamentals of lean
What You Will Learn:
- Improving business performance is the theme of the workshop.
- The two-day Lean Simulation Bootcamp uses a production simulation to teach fundamental Lean practices and connect these practices to business objectives and the profit and loss statement.
- Specifically, participants will learn how 5S, 7 wastes, kanban, level loading, flow, data analysis, value stream mapping, and Toyota Kata contribute to improved operations and profitability.
- Participants will perform several rounds of the simulation. Performance improves with the introduction of various Lean practices in each round.
- The profit and loss statement is updated and analyzed when each round is completed.
- The workshop ends with the participants developing an initial plan to apply the practices and methods in their own work environment.
► DISCOVER THE FUNDAMENTALS of key Lean concepts in this fun, interactive, team-building workshop.
► EXPERIENTIAL LEARNING connects the implementation of these concepts with the strengthening of your organization's processes.
► REFLECT ON GAINS and the improvement of the process.
| Duration | Two Days |
|---|---|
| Topics | Lean strategy, 5S, 7W, Standard Work, Flow, line balancing, Value Stream Mapping, Toyota Kata, aligning with business objectives, customer focus |
| Primary Customer | Operations Manager |
| Secondary Customer | Operations Supervisor |
| Tertiary Customer | Continuous Improvement Specialist |
Day 1 – Building the Foundation
Morning (8:30 AM – 12:00 PM)
What You’ll Do:
- Learn key Lean concepts and connect them to your business goals.
- Map your current Value Stream and understand how work flows through your process.
- Participate in a hands-on simulation to experience batch processing and visual management.
- Update real-time process metrics and review your results with the group.
Afternoon (12:45 PM – 4:00 PM) (after Lunch Break)
What You’ll Do:
- Apply workplace organization (5S) and waste elimination (7 Wastes) in a live simulation.
- Measure improvements and review how the process changes affect results.
- Learn to standardize processes using Takt Time, Cycle Time, and Lead Time.
- Apply level loading techniques to balance workflow and reduce process variation.
- Run a third simulation to reduce batch size and improve flow.
- Participate in coaching debriefs and group discussions.
- Reflect on the day’s learning with a Plus/Delta feedback session.
Day 2 – Advancing Flow and Strategy
Morning (8:30 AM – 12:00 PM)
What You’ll Do:
- Review key lessons from Day 1 and discuss opportunities for improvement.
- Learn how to create flow using Kanban and pull systems.
- Participate in two live simulations focused on flow, bottleneck management, level loading, and True Pull.
- Measure results and update process visuals and P&L impact throughout the session.
- Engage in real-time coaching to connect process changes to business outcomes.
Afternoon (12:45 PM – 4:00 PM) (after Lunch Break)
What You’ll Do:
- Review the financial impact of Lean practices on business performance.
- Learn how to manage continuous improvement with daily practices and coaching techniques.
- Explore Toyota Kata routines to build daily improvement habits and develop problem-solving skills.
- Build a Lean strategy using the 4-Step Framework.
- Draft your own Lean roadmap to take back to your organization.
- Share final reflections in a Plus/Delta session to close the workshop.
What event types are available?
In-Person
At our Dallas-Fort Worth training center
Our modern, well-equipped training center gets your team all in one place, ready to tackle your improvement challenges.Virtual
From anywhere you have internet access
Unlike other webinars, our virtual training is designed to be engaging and impactful, regardless of where you are joining from in the world.On-Site
We come to your location
For your ultimate convenience, we can send a trainer directly to your facility to deliver training in your familiar surroundings.
Explore our other events.
Online
A3 Problem Solving: Interactive Webinar
$50 per person
Craft Clear Solutions with Precision
Are you looking for a reliable way to solve problems that drive real, lasting improvement? This virtual A3 problem-solving workshop is based on Toyota’s Lean management approach and teaches a structured method for identifying root causes, developing effective countermeasures, and communicating solutions clearly. If your team struggles with recurring issues or lacks a consistent problem-solving process, this session will give you the tools to create sustainable change.
Learn More & Register
Online
FREE Leadership Webinar
Why Change Slows Down: What Leaders Do to Sustain Momentum
FREE event hosted by Gemba Academy!
Most change initiatives don’t fail dramatically. They slow down. Momentum fades, leadership reinforcement weakens, and old habits quietly return.
Even well-funded, well-intentioned improvement efforts can lose traction when leadership behaviors and systems don’t consistently support them.
This session explores why change stalls and what leaders do differently to sustain momentum over time.
In one focused session, you’ll gain practical insight into the leadership patterns that either accelerate progress or quietly undermine it.
No classes currently scheduled.
Dallas-Fort Worth, TX
2-Day Toyota Kata Experiential Workshop
$1,850 per person
Join us for a 2-Day in-person workshop located at the Gemba Academy training facility centrally located in the Dallas-Fort Worth area in Keller, TX.
This interactive workshop is designed to help you build confidence with Toyota Kata, from learning the foundations to practicing real-world coaching. Over two days, you will discover how to develop new skills, apply scientific thinking, and gain hands-on experience that prepares you to coach others effectively.