Gear Factory

The Gear Factory is a learning laboratory that lasts two days during which the attendees simulate the path of Lean Transformation, which a real manufacturing company usually carries out within a period of 12/24 month.
After reaching the Lean stage, the participants transform the Gear Factory into a smart factory, applying the 9 technologies that constitute the paradigms of the Industry 4.0.

Thanks to the highly experiential approach that uses mini work stations to produce electric motors, the participants lead the transformation of the company according to the Lean principles, learning to improve the core processes applying the most appropriate Lean tools in compliance with the delivery times, costs and quality required by the market.

The path of Lean Transformation is simulated in 4 rounds, divided into two days. Participants can experience how the 7 typical wastes of the lean methodology (waiting times, overproduction, stocks…) hide in traditional companies, usually organized in work cells.
Participants learn to measure and analyse data collected using methods and tools typical of Lean Thinking such as the spaghetti diagram and the value stream map in order to re-design the production and information flow.

During the various rounds the attendees put into practice continuous improvement working in a team and learning to:

  • apply the most appropriate methodological tools to the different critical situations
  • implement sophisticated tools like the yamazumi chart
  • organize stock management by applying kanban, supermarket and visual management
  • address issues such as ergonomics and time&motion analysis

During the last round, the I4.0 technologies are implemented in the Lean-turned factory completing the transformation into a smart factory, digitalizing some of the processes already improved in the previous rounds. Participants can experience some applications such as:

  • real-time production progress
  • real time plant performance
  • display of standard operating procedure
  • parameter control with wearable technologies
  • autonomous internal logistic.