The Seven Wastes – Factory Simulation Game image

Improvement Toolkit / The Seven Wastes – Factory Simulation Game

This training is part of a wider training program. It helps people develop the 7 wastes for themselves, and arrive at the tactics required to do something about them. This is very good for helping people understand improvement, and generates long term sustainability – however, it should be considered a 2nd phase initiative – it does not provide sufficiently rapid results for 1st phase interventions.

This lively factory simulation game teaches the principles of the 7 wastes.

  1. Operator movement
  2. Transportation
  3. Defects
  4. Waiting (Idle Time)
  5. Inappropriate Processing
  6. Overproduction
  7. Unnecessary Inventory

The team are given a simulated assembly operation to operate, and learn through practice, trial and error how to improve it. Along every step of the way, the performance is measured – which allows the team to see the impacts of removing waste on profit.


Lean game table_7wastes


By the end of the game, participants can identify each type of waste in their own work area, and know how to go about reducing them as part of the day to day – and they’ll have great fun along the way. Don’t take our word for it, see some of the feedback we’ve received from those who have participated:


  • ‘I had heard of the Seven Wastes before but didn’t know what to expect when I came on the course, I thought I might get bored but it was excellent. It was also fun.
  • ‘Very enjoyable course learning wastes in the factory and saving company money
  • ‘The particular aspect of the course that I liked was the interactive nature – learning from doing.’

Interested in 7 wastes, but not sure if it is for you? Look at the Assessment & Planning page to see how to plan your improvement programme.

This course can be run stand-alone, in both executive level and operator level variants – as well as part of a customised programme. If you think you might be interested in this kind of workshop, but you’re not sure – contact us and we’ll tell you what is most appropriate for you.



Sound like something you might be interested in? 



It’s been running so well, we could do a crossword!


It’s brilliant! We used to produce 3 or 4 full bins of waste a day now we’re down to less than ½ a bin! The final bit of work we do should reduce it to virtually nothing!

Operator – Branded Bakery