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International Automobile Manufacturer

An Experiential Alternative to Measure Plant Waste Elimination

Plant operations and learning leaders for this global automotive manufacturer sought an innovative method for objectively determining the effectiveness of their Six Sigma Waste Identification and Elimination classroom and web-based training program. The initial idea was to film a series of videos throughout a typical manufacturing plant, have learners answer questions related to identifying the instances of waste they observed, and identifying what forms of remediation they would apply to eliminate the situation.

While this suggested assessment approach represented a viable and engaging option compared with existing methods, the opportunities for capturing the level of data required to comprehensively assess each learner’s level of understanding and their ability to apply that knowledge were limited. As an alternative, Mosaic recommended an experiential simulation method utilizing our online 3D gaming platform to create a highly interactive plant environment capable of objectively capturing detailed performance data on each participant’s actions and decisions for evaluation.

A Valuable Opportunity to Capture Attention and Detailed Performance Data

Mosaic designed and developed a 3D post-training practice and assessment simulation that replicates a typical manufacturing plant. Learners use their keyboard and mouse to move virtually throughout the plant and attempt to locate all instances of waste, categorize the specific type of waste with applicable tagging, and determine the appropriate remediation method for eliminating the waste.

Key performance data points tracked during each scenario simulation include:

  • The number of wasteful situations correctly located
  • The number of identified instances tagged properly for the type of waste
  • The number of accurately determined methods for eliminating waste
  • Time to complete specific tasks and the entire simulation
  • Identification of best practice inconsistency trends amongst participants for training improvement

Mosaic recognized an opportunity to further engage and entice active participation in all aspects of the program’s training and assessment process by establishing an atmosphere of “friendly competition.” We created a dynamic “Leaderboard” that presents after each completed simulation, detailing how each participant ranks amongst their peers in real-time.

Electric Gas Pipeline