Game based learning of lean manufacturing: decreasing personnel resistance

Abstract

Developing production systems based on the principles of lean manufacturing is getting more and more popular nowadays. At the initial stage one of the main issues is high personnel resistance. Training helps to overcome the staff resistance. The research aims at proving a hypothesis of the positive effect of game based learning methods with imitating the production process on lessening the personnel resistance at the stage of implementing lean manufacturing in the company. The paper describes the game model worked out by the authors. This model imitates the production process consisting of successive operations. In the model two main factors influencing the productivity are taken into account: defective goods and stand by time. The model was tested at an enterprise producing children toys made of rubber and plastic. As a result, the participants have learnt some basic principles of lean manufacturing, as well as a principle of forming the key index of Overall Equipment Effectiveness (ОЕЕ). The task of lessening the personnel resistance was solved, the participants got to understand the necessity of improving the production process. The model is universal and is easily applicable to any productions and non-production processes. The authors believe the research has a broad sphere of applicability.