Lean Simulation Game


Lean Manufacturing was pioneered by Toyota, and is an all-encompassing approach to maximizing overall organizational efficiency. Equally applicable to manufacturing and service businesses, Lean has been successfully implemented in thousands of leading companies worldwide. This 1/2 day highly interactive workshop is targeted at all levels of an organisation and allows everyone to experience the power of Lean first-hand.


This workshop demonstrates the application of Lean concepts in a “game” where participants are workers in a robot factory.  Using lego blocks as raw materials, the workers assemble, inspect and ship the completed robots.  As the game runs, Lean concepts are introduced and the participants experience first-hand the power of implementing Lean.  This workshop is a perfect add-on to the Executive Lean Overview session to cement the key Lean concepts and:

  • Prove “Lean” works
  • Understand why “Lean” works
  • Better understand the benefits of Lean

What You Will Learn

The workshop synopsis is as follows:

  • Introduction
    • Game description
    • Rules
  • Round 1 – Mass Production
    • Run the game
    • Collect data
    • Analysis
  • Round 2 – One-Piece Flow
    • New Work Layout
  • Round 3 – Balanced Work
    • New assembly instructions
  • Discussions / Review

Training Outcomes

Participants will have a basic understanding of the concepts of Lean Thinking, and be able to provide the appropriate leadership to ensure the success of their Lean transformation effort.


Training Overview

Our Courses

Manufacturing Control Systems

Quality & Environmental Systems

Strategy & Execution

Improvement Tool Kit

Presentation & Leadership Skills

Full Course List


SatiStar's Experience Makes The Difference!

  • . . . worked extremely well with the departmental and site managers . . . goal oriented and met the objectives set within the quoted budget and ensured the results were attained for the Company.

  • The guys from SatiStar did more in one week than we were able to do in 6 months.

  • Achieving ISO registration was far less onerous than we thought, our employees really rallied to the cause. The registration effort really brought us closer together as a team, and SatiStar really came through for us when we needed them.

  • We started this process a year ago with Mickey helping us create a spaghetti map of our processes on the whiteboard, and then his team guided us through their streamlining methodology and got us to where we are today. Our processes now look nothing like the spaghetti map – and we’re much more efficient today

  • This projected cycle time reduction of over 80% annual cost savings amounting to over 3% of sales, one-time savings of roughly $10 million, and working capital reduction of roughly $30 million really have us excited!

  • An outstanding success with Motorola’s vendor audit! What made this an exceptional achievement is that it typically takes 4 to 5 attempts to pass this audit. SatiStar’s expertise made it easy to avoid all the extra attempts.