Business Process Simulation: Moving from Dysfunction to Distinction
One of the primary reasons that companies are unable to adopt best practices―or that new methodologies do not “stick” once implemented―is that personnel cannot adapt their mindsets to embrace the new approaches. To use an informal but appropriate euphemism, they simply cannot “wrap their heads around it.”
Unfortunately, this change resistance hinders reliability improvement, trips up preventive maintenance programs, encumbers spare parts management and leads to unplanned downtime. So what’s the solution? Gamifying the continuous improvement experience—or more appropriately, simulating it.
The PCA Simulation at a Glance:
- What Is a PCA Simulation? A PCA simulation is a hands-on workshop designed for maintenance, repair operations and inventory management teams. It helps them go from reactive to proactive work processes in a short time.
- How Long Does the Simulation Last? The simulation takes about a day and a half, with part of day two reserved for debriefing and discussions about plant operation improvements.
- Why Participate in the PCA Simulation? Participants collaborate to implement real-world best practices to make plant operations 80% or more proactive using 14 KPI measurements.
What Happens in a PCA Simulation?
In just two days, participants simulate four weeks of activities, learning how to shift from reactive to proactive work processes.
Participants witness firsthand how adopting new approaches leads to better spare parts management, industrial maintenance and improved uptime.
Some of the key concepts covered during the simulation include the following:
- Failure analysis
- Operations and maintenance
- Storeroom optimization
- Industrial maintenance
- Equipment repair
Throughout the simulation, we will reinforce concepts like preventative maintenance, proactive equipment repair, inventory optimization and spare parts management. After completing the simulation, your team will be better equipped to respond to equipment needs and remove deferred maintenance from your workflows.
How Long Does the Simulation Last?
PCA recommends that you allocate two full days to the simulation:
- Day 1 and Day 2 (AM Session): Gameplay (Four 75-minute rounds)
- Day 2 (PM Session): Facilitated debrief and discussion of improvement opportunities
Our facilitator will pause the clock throughout the rounds to compare what’s happening in the game to a real-world situation. These teaching moments are invaluable for transferring the lessons learned during the game to the facility’s ongoing maintenance processes.
Benefits of the Simulation
PCA facilitators use the simulation and the organic teaching moments it affords to impart the following benefits to your team:
- Increased understanding of the value of proactive maintenance
- Recognition of the link between scheduling and parts-management processes
- Practical knowledge regarding the role of collaboration in proactive maintenance
- Experience finding best-practice solutions to daily problems
During the debriefing, our facilitators will promote critical thinking and encourage participants to apply the lessons they have learned to real-world organizational challenges they encounter every day.