2-Day Lean Simulation Bootcamp

Seats are limited, so bring your team and get hands-on with lean. In this two-day workshop, you’ll work through a production simulation to see how methods like Toyota Kata, 5S, Flow, and Pull improve performance. Track your results through real process metrics and P&L statements, gaining practical insight you can take back to your workplace. Held in person at Gemba Academy’s training facility in Keller, Texas.

Who is this for?

• Frontline, CI, and Operations professionals at all levels.

Why Should I Attend?

• Eliminate pain points and friction
• Increase velocity
• Increase profits
• Boost employee engagement while experiencing the fundamentals of lean

Day 1 – Building the Foundation

Morning (9:00 AM – 12:00 PM)
What You’ll Do:

• Learn key Lean concepts and connect them to your business goals.
• Map your current Value Stream and understand how work flows through your process.
• Participate in a hands-on simulation to experience batch processing and visual management.
• Update real-time process metrics and review your results with the group.

Afternoon (12:45 PM – 4:00 PM) (after Lunch Break)
What You’ll Do:

• Apply workplace organization (5S) and waste elimination (7 Wastes) in a live simulation.
• Measure improvements and review how the process changes affect results.
• Learn to standardize processes using Takt Time, Cycle Time, and Lead Time.
• Apply level loading techniques to balance workflow and reduce process variation.
• Run a third simulation to reduce batch size and improve flow.
• Participate in coaching debriefs and group discussions.
• Reflect on the day’s learning with a Plus/Delta feedback session.
  

Day 2 – Advancing Flow and Strategy

Morning (9:00 AM – 12:00 PM)
What You’ll Do:

• Review key lessons from Day 1 and discuss opportunities for improvement.
• Learn how to create flow using Kanban and pull systems.
• Participate in two live simulations focused on flow, bottleneck management, level loading, and True Pull.
• Measure results and update process visuals and P&L impact throughout the session.
• Engage in real-time coaching to connect process changes to business outcomes.

Afternoon (12:45 PM – 4:00 PM) (after Lunch Break)
What You’ll Do:

• Review the financial impact of Lean practices on business performance.
• Learn how to manage continuous improvement with daily practices and coaching techniques.
• Explore Toyota Kata routines to build daily improvement habits and develop problem-solving skills.
• Build a Lean strategy using the 4-Step Framework.
• Draft your own Lean roadmap to take back to your organization.
• Share final reflections in a Plus/Delta session to close the workshop.

What You Will Learn:

• Improving business performance is the theme of the workshop.
• The two-day Lean Simulation Bootcamp uses a production simulation to teach fundamental Lean practices and connect these practices to business objectives and the profit and loss statement.
• Specifically, participants will learn how 5S, 7 wastes, kanban, level loading, flow, data analysis, value stream mapping, and Toyota Kata contribute to improved operations and profitability.
• Participants will perform several rounds of the simulation. Performance improves with the introduction of various Lean practices in each round.
• The profit and loss statement is updated and analyzed when each round is completed.
• The workshop ends with the participants developing an initial plan to apply the practices and methods in their own work environment.

► DISCOVER THE FUNDAMENTALS of key Lean concepts in this fun, interactive, team-building workshop.

► EXPERIENTIAL LEARNING connects the implementation of these concepts with the strengthening of your organization's processes.

► REFLECT ON GAINS and the improvement of the process.

What if these dates don’t work for me?

If you’re interested in upcoming public class dates or would like to book a private training session at our Keller Training Center, we’d be happy to help. Reach out to us at events@gembaacademy.com for more information, or visit our Events page at gembaacademy.com/solutions/events.

About Gemba Academy:

Gemba Academy is a leading provider of continuous improvement training, helping organizations and individuals build a culture rooted in Lean, Six Sigma, and operational excellence. Since 2009, we’ve supported companies of all sizes, from small businesses to global enterprises, through a flexible mix of online training, expert-led live instruction, coaching, and industry-recognized certifications. With over 2,000 practical videos covering proven methodologies and leadership strategies, our training delivers immediate value by equipping professionals to solve problems, lead effectively, and drive sustainable improvement. To learn more about Gemba Academy’s online content, in-person training events, expert coaching, and certifications, please visit https://www.gembaacademy.com/?utm_campaign=Live+Events&utm_medium=referral&utm_source=eventbrite&utm_content=Homepage

See more of what Gemba Academy has to offer:

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Location and Areas of Interest:

The Gemba Academy training center in Keller, Texas is nestled in the heart of the Dallas-Fort Worth Metroplex with easy access to dining, museums, parks, and many other attractions.

Local Airports:

DFW Airport (14 mi)

Southwest Airlines (27 mi)

Hotels:

Courtyard Marriot, Alliance Town Center (4.4 mi)

Hampton Inn, Keller Town Center (1.5 mi)

Hyatt Place, Fort Worth/Alliance Town Center (6.5 mi)

Hilton Garden Inn, Fort Worth/Alliance Airport (6 mi)

Dining and Attractions:

Hutchins BBQ (5.3 mi)

Fort Worth S tockyards (15 mi)

Southlake Town Square (7 mi)