Lego Fun for All !

Phoenix conducted "Lego Training" for all associates last week. This 4-hour training exercise was conducted in three different sessions to allow all associates an opportunity to participate. This training simulates order fulfillment in our warehouse environment. Each group had an opportunity to run the same simulation three times, but were allowed to make improvements between simulations. As expected, every group dramatically improved their performance in each simulation. The improvement from the baseline simulation to the final was dramatic!

Trainees learned about process mapping and practical ways to apply Lean Thinking in their work areas. They used spaghetti diagrams to identify and reduce motion. They applied 5S in their work areas. They applied visual controls. They redesigned work areas and operational floor layouts. Between simulations, they received instructions on some new tools, then had the chance to apply those tools, and others they already knew, on the simulated work floor. They had limits and time constraints, just like real life! They discussed ideas and found ways to implement the ideas with greatest impact.

In the end, most associates found the training to be helpful in understanding Lean Thinking. But more importantly, they learned new ways of how to apply Lean in their work areas. In addition, it became obvious that Lean becomes much more impactful in the work place when associates share their good ideas and understanding of our functions with each other and their leaders. What may be obvious to them is sometimes overlooked by those who don't work that job every single day!