✈️ LEGO AIRCRAFT FACTORY: Work Hard or Work Smart?

Do you have one operator running nonstop on your production line while another finishes their work and waits?

🛑 Does your production flow keep getting stuck even though your total capacity seems sufficient?

An efficient production line should flow like a highway without traffic congestion. When the rhythm breaks down, there is usually an imbalance — and waste.

LEGO Aircraft Factory is a hands-on training kit designed for in-house Lean training. Instead of simply discussing line balancing in theory, participants step directly into a simulated production flow, discover bottlenecks, and test their solutions by eliminating waste and improving the process.

🎯 With LEGO components, workstation posters, Standard Work forms, and a comprehensive Trainer Guide included in the kit, the simulation can be run repeatedly by your own teams without requiring external consulting support.

🚀 Three Rounds from Chaos to Flow

This hands-on training kit takes participants through three production rounds:

1. 🧱 ROUND 1 — Chaos

Without Standard Work or clear production instructions, participants experience the variation and scrap costs created by trying to produce without a clear process.

2. 🔧 ROUND 2 — Standardization

Using 5S and Standard Work, the team improves quality but discovers the bottlenecks created by an unbalanced workload.

3. ⚖️ ROUND 3 — Smooth Flow

Using Yamazumi analysis and Kanban, participants learn how to create a continuous flow aligned with customer demand and Takt Time.

🔍 What Will Your Team Gain?

• 📈Yamazumi: Develop the ability to balance workloads using a structured approach.
• ⏱️Takt Time Focus: Understand why production rhythm matters more than simply working faster.
• 💰Financial Awareness: See through the game scores how overproduction, WIP, and defects affect business profitability.
• 📝KPT Technique: Define what to Keep, which Problems to address, and what to Try immediately after the training.

Turn your team's ability to create value into measurable performance, and use Lean methods to remove the bottlenecks in your production flow.

For detailed information and a quotation for the simulation kit, please contact us:

📧 info@yalinnetwork.com