2-Day Lean Simulation Bootcamp

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.

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.