Theory

Before each work shift begins, participants receive a theoretical briefing on the tasks at hand. Topics may include the importance of maintenance, the role of the process operator in quality assurance, or how to handle an overfilled buffer stock. Each shift has its theoretical connection to give participants an understanding of the manufacturing process and their role within it.

Practical Work

After the theoretical briefing, the work begins. Participants are divided into pairs and assigned to keep production running while responding to unexpected events — machines may malfunction, colleagues may experience accidents, or the production line may come to a sudden halt due to issues further down the process.

During the work shifts, participants are challenged to work smart, efficiently, and, most importantly, safely. Team leaders constantly monitor the factory floor to see if participants can remain calm and follow safety regulations while performing their tasks.

Reflection

Just like in a real factory, reporting is a crucial part of the work. After each shift, every pair’s results are recorded on team boards. These results then form the basis for reflection, where participants discuss how their actions influenced the shift’s outcome.

Here, safety is once again in focus — participants are closely monitored on how well they adhere to safety regulations. The rules are few and simple, but remembering them in the heat of the moment is not always easy.

Outcome

After completing the BPT training, participants have learned what life on the factory floor is like. They have developed teamwork skills — not only with their partner but also with the entire team — to achieve the best possible results. They also gain a deeper understanding of how a factory operates and the vital role of a process operator.

A major advantage of BPT training is that it is both fun and engaging! The pursuit of strong delivery numbers introduces a competitive element that helps create an exciting atmosphere in the simulated factory.