SUCCESS STORIES

Background: 

GMi partnered with LeanGo to enhance operational efficiency through the Lean Lego Simulation training, led by Katie Myers. Over 20 team members from Trophy Case, Aluminum Reversible, and Pack Line departments attended the sessions on March 27th and 28th. 

Sessions Overview: 

• Led by: Katie Myers, LeanGo Training Partner 

• Attendees: Over 20 team members 

• Format: Two half-day sessions with interactive challenges 

• Location: GMi headquarters, utilizing a well-equipped training room and a simulated practice area 

Training Activities: 

• Practical application of Lean practices like 5S, Kanban, Continuous Flow, and Labor Balancing in a simulated production environment. 

• Building Lego race cars to demonstrate and practice Lean concepts. 

Goals and Participants: 

The goal was for each participant to gain two actionable improvement ideas. Area leaders attended to support their teams for upcoming Kaizen events. 

Outcomes and Feedback: 

• Production Costs: Reduced by 25% 

• Inventory Levels: Decreased by 40% 

• Lead Times: Shortened by 30% 

• Defect Rates: Lowered by 50% 

• Employee Productivity: Increased by 20% 

Participant Feedback: 

• "The Lego production flow showed us how lean manufacturing is beneficial." 

• "Practicing with Legos improved our teamwork and processes." 

• "I enjoyed the team-building and hands-on experience." 

• "Small changes make a big difference." 

• "Continuous improvement is always possible." 

Conclusion:

LeanGo’s Lean Lego Simulation training significantly improved GMi’s operations, reducing cycle times by half and freeing up warehouse space for better material organization. The success story demonstrates the powerful impact of Lean principles in achieving operational excellence 

Lean Lego Simulation Transforms Operations at GMi