The Airplane Game
(PDF Flier and Order Form)

• Visual, hands-on demonstration of how changes can improve productivity.
• Dramatic results reinforce the experience.
• Excellent method to break down paradigms.

Lean Zone® Production Methodologies

Lean Zone® Production Methodologies, a cellular manufacturing simulation, has been sold to over 28 countries, and is widely used by Fortune 500 companies and other large organizations, including Bell Helicopter, Price Waterhouse Coopers, Lockheed-Martin, Black & Decker, and Eastman-Kodak as a vital training tool.

Lean Zone® Production Methodologies helps break down employees' natural resistance to change, making it a practical and entertaining way to introduce new concepts, open constructive dialogue and demonstrate the positive aspects of well-planned directed change. Employees involved in the simulation see why lean Production Methodologies is necessary. It helps to remove their fears regarding change and encourage them to identify non-value added activity. Using a fictional aircraft factory, Lean Zone® Production Methodologies also specifically teaches advanced manufacturing practices, including:

• The benefits of cellular manufacturing over traditional plant layouts
• The effects of rapid throughput with traditional manufacturing
• Work-in-progress as a manageable asset
• Inventory risks
• Independent cross training
• Flexible workforce (load leveling)
• One-piece workflow with a pull system

Six participants operate simulated workstations along the assembly line in their imaginary aircraft plant. The four-phase simulation begins with participants producing airplanes using a traditional plant layout. In phases two and three, they redesign their work area into a cellular layout and learn to utilize one-piece workflow with a pull system. In the final phase, they experience the concepts of a flexible workforce and load leveling.

Supplier problems, labor skills, deadlines, quality control and other real-life situations have been incorporated into each phase of the simulation. Each phase lasts six minutes with time for comments and discussion.

Each Lean Zone® Production Methodologies kit includes:

• 20-page instruction manual
• Charts
• Stopwatch
• Feeler gauge
• Markers
• More than 1000 plastic interlocking parts for constructing airplanes

Many organizations spend hundreds of dollars per person on lengthy seminars for employees to learn what Lean Zone® Production Methodologies can teach in as little as one hour - all for only $425. We ship internationally!

Download PDF Flier and Order Form here.