Lean Six Sigma Simulation

In the simulation, participants will:

• Define a project charter based on business goals and customer needs.

• Measure current process performance using key metrics and data collection plans.

• Analyze data to identify root causes of defects, waste, and delay.

• Improve the process by generating, selecting, and testing potential solutions.

• Control the new process by developing monitoring plans to sustain gains.

• Manage project resources, timelines, and team dynamics.

• Present findings and justify recommendations to a simulated leadership team.

• Compete or collaborate with other teams to achieve the best operational and financial outcomes.

• Apply a structured, hypothesis-driven approach to solve ambiguous business problems.

• Utilize key consulting frameworks to analyze competitive landscapes and internal capabilities.

• Transform data analysis into coherent, actionable business insights.

• Craft and deliver a compelling, client-focused narrative.

• Manage team workflow and dynamics under time pressure.

• Confidently present recommendations and handle pointed stakeholder questions.

• Understand the core drivers of value and impact in a consulting engagement.

1. Receive the Project Brief Teams are introduced to a problematic operational process (e.g., order fulfillment, manufacturing line) with baseline data.

2. Diagnose and Analyze They review process maps, collect additional data, and use tools to identify the largest sources of waste and variation.

3. Make Strategic Decisions Teams decide which improvement strategies to fund, which tools to apply, and how to manage stakeholder expectations.

4. Collaborate and Negotiate Participants may assume different roles (Black Belt, Sponsor, Process Owner) and must work together to align on priorities.

5. Implement and Monitor Teams roll out their solutions, face unplanned consequences, and adjust their control plans.

6. Review and Reflect Instant feedback shows the impact of their decisions on key metrics (cycle time, cost, defect rate). Teams refine their approach in subsequent rounds.

• Who is this Lean Six Sigma simulation designed for? It’s ideal for professionals and students in operations, manufacturing, supply chain, healthcare, and business process management, as well as anyone pursuing Yellow, Green, or Black Belt training.

• Do I need prior Lean Six Sigma experience? No prior experience is required. The simulation includes foundational instruction and is designed for learners at all levels.

• How long does the simulation run? Typically 2-4 hours, but it can be modularized into shorter sessions or extended into a multi-day workshop, depending on the depth of exploration.

• Is the simulation individual or team-based? It supports both formats and is highly effective for fostering teamwork and cross-functional collaboration, mirroring real project team dynamics.

• What methodologies are covered? The core focus is on the DMAIC framework of Six Sigma, integrated with key Lean tools for waste reduction, such as Value Stream Mapping and 5S.

• Are real-world data and scenarios used? Yes. Participants work with simulated but realistic process data and scenarios based on common industry challenges.

• Can the simulation be customized for our industry? Absolutely. Process scenarios, key metrics, and complexity can be tailored to reflect specific sectors like healthcare, finance, or logistics.

• How is performance measured? Performance is evaluated based on the achievement of project metrics (e.g., % defect reduction, cost savings), effective use of the DMAIC methodology, quality of data analysis, and clarity of stakeholder communication.

• Adherence to and mastery of the DMAIC methodology.

• Improvement in key process performance metrics.

• Effective application of Lean and Six Sigma tools.

• Financial impact and return on investment of their project.

• Clarity and persuasiveness of their final project presentation.

• Team collaboration and adaptability in response to challenges.