Synchro game - an introduction to lean production & value stream mapping

Course Summary
The Synchro Game is a business game that uses a model production system to introduce participants to the principles of lean and to help them understand how they can deliver efficiency and production gains.

During the game the participants form the Synchro Corporation and are tasked with designing and setting up a real production line. Their aim is to produce products to fulfill customer orders and deliver them on time. The game begins with the participants taking the roles of the customer, supplier, production, quality, accounting, stores, planning and scheduling and discussing amongst themselves how to organize production steps to fulfill customer orders on time.

Once the planning phase is completed, the game runs. The orders flow, production begins and the team experience first hand the results of their decisions. It’s often a hectic and stressful time.

After each round of the game the individuals evaluate the company’s performance and guided by the trainer analyze the causes of the delivery problems and low productivity. Bottlenecks are identified and the team develop ideas for improvements which are implemented in subsequent rounds. The trainers take the opportunity to introduce specific methods, tools and techniques to the participants and encourage them to incorporate them into the planning process. Before the final round all the techniques and methods learnt are brought together and we and use value stream mapping to design the ideal process before putting it into practice

Target group
The Synchro Game is aimed at companies and individuals that are confronted with production control processes and want to develop a general understanding of the principles and impact of lean thinking and how these could be put to use in their organisations.

Syllabus (covered where appropriate)

• Inventory minimisation as an important basis for increased productivity
• The principle of ‘pull’ production control
• Advantages compared to traditional production control methods
• An overview of value stream mapping
• Identification of bottlenecks
• Calculation of Overall Operating Efficiency (OEE)
• Understanding of the impact of Single Minute Exchange of Die (SMED) 
• Applications of the methods
• The classic pull principle: KANBAN
• Practical implementation of a business game in a model production system
• Continuous Improvement Production (CIP) processes as part of the business game
  

Training outcomes

• Understand that production gains can be achieved through careful planning of the marterial and information flow
• Understand that product gains can be achieved without spending lots of money 
• Understand the terminology and principles associated with Lean Thinking.
• Understand and be able to describe seven forms of waste in a manufacturing process
• Understand the term Value Stream Mapping (Analysis) and know the principles of how to apply it.
   

Course Duration
Courses are completed in two days and are available in-company or at one of our national training centres.

Price 
£500 open course place, £7,500 in company course.

Customised training
If you are planning to introduce a pull production control method in your company, we recommend running this business game directly in the company.

Special Offer
We are offering a free 1.5 hour taster session on 13th May 2010. Anyone that takes up this offer will be entitled to 2 places for the price of one on our full course in June 2010* (Usual price £500). Attendees on this course will in addition receive 50% off the cost of their first in-company course (Usual price £7,500)*. This special offer is subject to our terms and conditions.

*Terms & conditions. The Special Offer is only valid for new course bookings and is subject to course availability at time of booking.

To discuss this seminar in more detail over a coffee, please contact the business centre on (01604) 667584 or alternatively, e-mail business_centre@festo.com.