Karlstad lean factory: an instructional factory for game-based lean manufacturing training

Abstract

Simulation for training lean manufacturing ranges from simple paper-based or LEGO®-based games to larger scale simulation environments, for instance push car assembly. Some models for game-based learning are discussed and a model for lean manufacturing training is adopted. Many types of simulation may be suitable for teaching some basic elements of Lean manufacturing to students, but they are often less suitable for training industry workers in applying Lean manufacturing in their work environment. The latter group is more used to intuitive learning than to formal instruction. Thus, it is important that a training environment for this group more realistically represents the work environment; otherwise training transfer will be limited. For this reason, a lean training environment that includes materials processing stations as well as assembly areas was created. The stations exhibit some realistic behaviour such as stochastic breakdowns. Based on a comparison between factory workers and university students, five hypotheses for testing in future work are proposed.