🚛 LEGO VSM Simulation: Discover Value Flow with the “Modular Truck Factory”

When evaluating efficiency in a factory, we often focus on how quickly operators work — in other words, on Cycle Time.

But there is a hard reality:

Around 95% of the time a part spends in a factory is not spent being processed. It is spent waiting in a box.

At Yalın Network, we believe training should go beyond theory. Real learning happens when people experience the process themselves.

Built around this philosophy, the LEGO VSM Simulation: “Modular Truck Factory” is a dynamic training tool that makes complex production processes visible using simple LEGO components.

⏱️ How Can a 15-Second Task Take 10 Minutes to Deliver?

The simulation is built around a critical question:

“If assembling a truck takes only 15 seconds in total, why does it take 10 minutes to deliver it to the customer?”

Together with the participants, we map and analyze these hidden waiting times — the Muda — using Value Stream Mapping (VSM).

🚀 From Chaos to Lean Flow

This intensive training session takes approximately 2–2.5 hours and guides participants through the following stages:

1. Current State

Participants experience firsthand the inventory buildup, long lead times, and chaos created by traditional Push and Batch production, including sudden changes in customer demand.

2. Asakai & Value Stream Mapping

After the round, the data is collected and Takt Time is calculated.

The famous “sawtooth chart” is created to make the huge gap between value-added time and waiting time visible.

3. Future State Design

The team redesigns the process using techniques such as:

• Line Balancing
• Pacemaker selection
• SMED / Quick Changeover

4. Future State Implementation

The team puts its decisions into practice.

With One-Piece Flow and a Pull System, the improvement in production performance becomes directly visible.

📊 The Results: Data Tells the Story

Representative scenarios from the simulation demonstrate the potential impact of Lean transformation:

• Lead Time: Can decrease from 6 minutes to as little as 25 seconds.
• WIP: Can decrease from 12 parts to 1 part.
• On-Time Delivery (OTD): Can improve from around 40% to 100%.

👥 Who Is This Training For?

The Modular Truck Factory is designed for:

• Trainers who want to move beyond static presentations
• Managers who want to learn how to see waste in production processes
• Teams that want to experience Lean as a way of working and thinking

If you want to teach your teams how to see and use the power of simulation to identify and eliminate waste in your production processes, get in touch with us.

For detailed information and simulation kit inquiries:

📧 info@yalinnetwork.com
🌐yalinnetwork.com