Lean Awareness Workshop: Practical Insights Through a Lego Simulation
🌟 Lean Awareness Workshop – Reflecting on Hands-On Fun! 🌟
Posted By: Neil Betts
Last week, I had the pleasure of running a Lean Awareness Workshop designed to transform the way teams think about processes, waste, and improvement. What made it special? We used Lego helicopters to simulate a real repair process! It was practical, engaging, and offered eye-opening insights into the power of Lean thinking.
Lean Awareness – Why a Simulation?
The best way to understand Lean principles is to experience them firsthand. Simulations let participants uncover inefficiencies, test improvements, and see the impact of change in a safe, hands-on environment. By turning theory into practice, simulations bridge the gap between learning and doing.
The Lean Awareness Workshop Setup: Lego Helicopter Repair Process
We simulated a process where our team had to strip, repair, and assemble Lego helicopters. Each round of the simulation clearly showed how Lean tools and a Lean mindset can drive significant improvements.
The 3 Rounds of the Simulation:
Round 1 – The New Process
In the first round, the team followed standard operating instructions, but the process was new. As a result, none of the 9 helicopters made it back into service, and only one passed quality control!
Key takeaway: Despite having instructions, hidden inefficiencies caused the process to break down, and quality suffered.
Round 2 – Team-Led Improvements
For the second round, we empowered teams to identify problems and propose changes. After tweaking workflows, the team managed to get 2 helicopters successfully inspected and back into service.
Key takeaway: Improvements happen when teams collaborate, but without Lean tools, progress can be limited.
Round 3 – Lean Thinking Applied
In the final round, we applied Lean principles—reducing waste, improving flow, and focusing on value. As a result, the team built, inspected, and returned all 9 helicopters to service efficiently.
Key takeaway: Lean tools unlock a team’s full potential, enabling them to achieve consistent, high-quality results.
Key Insights Gained
By running this simulation, participants discovered:
- The cost of waste: Inefficient processes waste time, effort, and resources.
- The value of teamwork and problem-solving: Teams perform better when given ownership and a clear process.
- The power of Lean: Lean thinking isn’t about working harder—it’s about working smarter.
“Gain practical insights into Lean by doing a simulation” is more than just a catchphrase—it’s a transformational learning experience.
Why This Matters for Your Business
The Lego workshop provides an accessible way to identify issues and inspire change. As a result, real problems become visible, and solutions emerge collaboratively.
Moreover, this workshop served as a powerful reminder that small changes can lead to a significant impact when Lean principles are applied. Whether you’re in manufacturing, services, or even creative industries, Lean truly has the power to transform the way you work.
Would your team benefit from a hands-on Lean experience? Drop a message and let’s make continuous improvement simple, engaging, and fun. 💡 💪
Learn more about the Lean Transformation Model