Learn Lean Manufacturing
in 7 rounds.
Heat pump HF-12 production line — realistic factory simulation where your decisions have immediate consequences. 7 rounds × 20 production periods. Bottlenecks, variability, defects — everything like on a real factory floor. Just without the risk.
to choose from
rounds
on production line
simultaneously
Theory does not teach decisions.
Lean Manufacturing is a strategy, not just words. Theoretical training teaches definitions — not choices under pressure.
E-learning
Knowledge without practice. Multiple choice tests do not simulate deadline pressure and limited budget.
Case studies
You learn from others' mistakes. You know what someone did, but not why in that specific order.
Simulation game
You learn from YOUR decisions, in a safe environment. Consequences immediate — not a month later.
You diagnose. You optimize. You measure.
📊 You diagnose
You run VSM (Value Stream Mapping), perform Gemba Walks, analyze variability (CV) and utilization of each workstation. You see where blockages and starvation occur.
🔧 You optimize
You choose from 25 Lean tools within an 8 pt/round budget: 5S, Kaizen, SMED, Kanban, SFM, Six Sigma, TOC Attack. Wrong order = wasted money.
📈 You measure
You see every KPI: delivered vs demand, OEE, WIP, defect rate, lead time. You learn to read data, not just theory. Without it — you buy tools blindly.
Demand grows. Pressure grows.
Each round is 20 production periods, demand grows from 40 to 70 units. After R5 it becomes a real stress test — everything you bought in R2-R4 must perform.
observation
+ foundation
test
Your arsenal. Choose wisely.
You have 8 pts of budget per round. Each tool is an investment — the effect depends on order and synergy. Selected examples:
| Tool | Effect | Cost |
|---|---|---|
| 5S | Order → reduces process variability | 2 pts |
| Kaizen | Speeds up operations at workstation | 4 pts |
| SMED | Quick changeover — setup reduction | 4 pts |
| Kanban | Buffer limits between workstations | 2 pts |
| SFM (Shop Floor Mgmt) | Foundation: CV −0.05 everywhere + ×1.3 boost to every tool | 3 / 5 pts |
| Six Sigma | Quality control, defect reduction | 4 pts |
| TOC Attack | Direct attack on bottleneck | 5 pts |
| …plus 18 more tools | ||
Score: Delivered × 3 + OEE × 2 + Lead Time + sequence bonus
What you really learn.
You'll understand "why"
"You'll see what causes delays and defects. You'll understand why your boss pushes 5S or Kanban — and what you'd do in their place."
Holistic thinking
"You'll learn that a single tool (e.g. Kanban) only makes sense in context — variability, bottleneck, decision order. Without the right organizational foundation, every tool loses ~30% of its impact."
Strategy in practice
"90 minutes of game = a lesson the participant remembers for years. Decision → consequence → repeat. The best known learning mechanic."
Diagnostics
"A perfect diagnostic tool: where does the player always lose money? That's where your intervention in the real plant will be."
Every session led by a practitioner.
Lean Factory is not a self-service game. Every session led by Adam Fieduk — 25 years of operations experience in production, working with companies across Europe, creator of the LEAI concept (Lean + AI).
What this means in practice:
- Pre-briefing — pre-game conversation about your industry and team challenges
- Live commentary — during rounds, commentary based on 25 years on the floor, not from a textbook
- Debriefing — post-game 30-60 min conversation on what to bring to your factory next Monday
- Follow-up — 2-week short call: what did your team actually change?
Ready to play?
Demo available as a presentation and walkthrough after a consultation with makeXcellence. Every session is tailored to a specific industry and team size.
BOOK A CONSULTATION →