Assembly, stations 1 to 4
Housing & motor, battery, chuck & test, packing. Every station has its own work steps and depends on the one before.
LeanActivity Online Game
How the Online Game works.
A Lean training your team plays in the browser: run a chaotic factory, measure it and make it Lean, round by round. About two hours, led by a moderator, for 2 to 20 players.
Round 12 ยท the Lean factory
Made for a moderator
One host leads the session, in the training room or in a video call such as MS Teams.
2 to 20 players in teams of 5
Up to four teams, each running its own factory, all at the same time.
Bots fill the free seats
Fewer players? Bots take over the free stations. To try the game, you can even play alone.
A session
Five steps from login to Lean factory.
No kit to unpack and no room to prepare. A session starts with a link and ends with a factory your team rebuilt.
Step 01
The moderator opens a session
As the host you open a session in the browser and choose the language. The lobby shows a link, a six-character code and a QR code: share them in your MS Teams call or on the screen in the room.
Step 02
Players join and design their worker
Everyone opens the link on their own computer, enters a name and designs a worker. Teams of 5 fill up on their own, up to four teams and 20 players. Bots take over every free seat, so even a small group runs the whole factory.
Step 03
Run the factory
Each player runs one of the four assembly stations or the logistics. Grab the parts, assemble cordless screwdrivers in the Light and Pro models and deliver the customer orders, all with the mouse.
Step 04
Measure and improve
After every shift the game shows the numbers of your factory. In the workshops between the shifts the team changes the factory together and in real time: everyone can move stations, plan the flow and test solutions.
Step 05
Compare and take it home
The final ranking adds up the Lean points of every team. Compare the first shift with the last, discuss what made the difference and take the lessons to your own shopfloor.
The 12 rounds
Five shifts, seven workshops.
In the shifts your team produces and feels the problems. In the workshops it changes the factory, and the next shift shows whether it worked.
- 01
- 02
- 03
- 04
- 05
- 06
- 07
- 08
- 09
- 10
- 11
- 12
5 shifts: the team produces7 workshops: the team improves
- Round 01Shift
The chaotic factory
Mesh pallets all over the hall, long walks and a forklift that cannot keep up. Your team runs the first shift and feels every problem.
- Round 02Workshop
5S
Everything that does not belong goes to the red tag area, and every station tidies up.
Round 03WorkshopLean layout
On the hall plan the team pulls the scattered stations together into one line. The walking distance per unit drops sharply.
- Round 04Shift
The new line
The second shift runs in the new layout: tidy stations, short ways, pallets between the stations.
Round 05WorkshopSMED
Changing over between the Light and Pro models costs time. With a shadow board or a one-touch slide, 20 seconds become 12 or even 1.
- Round 06Workshop
Plan one-piece flow
Roller conveyors replace the pallets between the stations: each unit goes on to the next station as soon as it is done.
- Round 07Shift
One-piece flow
Units roll from station to station one by one. No more piles of half-finished work in between.
- Round 08Workshop
Time study & line balancing
The team records the work content live at every station, then moves work steps until every station works below the takt.
- Round 09Workshop
Poka-Yoke
A motor goes in the wrong way round. The team tests three countermeasures and picks the one that makes the mistake impossible.
- Round 10Shift
The balanced line
The balanced, error-proofed line runs at an even pace. Every station has about the same amount of work.
Round 11WorkshopPlan the route train
The racks move to a fixed route, and a route train brings the parts from the supermarket instead of the forklift.
- Round 12Shift
The Lean factory
The final shift: the route train supplies every station on its loop. Now compare the numbers with your first shift.
After every shift
The numbers of your factory.
The game measures every shift for you and compares it with the rounds before. No stopwatch, no spreadsheet.
Output
Units delivered against the customer orders of the shift.
On-time delivery
How many orders reached the customer in time.
First delivery
How long it takes until the first finished unit leaves the factory.
Value-adding time
The time in the shift that actually builds product.
Rework
Time lost to units that have to be fixed after the test.
Changeover time
Time spent switching between the Light and Pro models.
Walking & transport
Time spent walking and moving material through the hall.
Work in progress
How many half-finished units wait between the stations on average.
Who does what
Roles in the factory.
Five seats per team: four assembly stations and the logistics. Every player has a job the others depend on; bots take the free seats.
Logistics
The forklift brings full mesh pallets to the stations and the customer pallets to the truck. In the last rounds a route train takes over the supply.
Moderator
Hosts the session, in the room or in an MS Teams call, starts the rounds, follows every factory live in the cockpit, sends hints to all players and presents the results.
What you need
A browser and your team.
- A computer with a current browser for every player, desktop or laptop
- An internet connection. Nothing to install, nothing to set up
- 2 to 20 players in teams of 5, in one room or remote in a video call such as MS Teams
- About two hours, including the discussions between the rounds
- One moderator who hosts the session: a trainer, a coach or you
- English or German, chosen by every player
Ready when you are
Your team, a chaotic factory and two hours. Let's make it Lean.
Play the demo for free, right in your browser. No installation, no setup, no credit card.