Our Industrial Simulation Approach and Methodology

At Lean Art, we combine industrial rigor and flexibility to deliver reliable, quickly actionable simulations and digital twins that are results-oriented.

The 5 Key Stages

We have developed an approach that blends the discipline of Lean Six Sigma with the adaptability of Agile.
The objective is to progress rapidly, deliver concrete results early, and continually adjust according to your needs.

Problem Definition

At the start of the engagement, we precisely define:
• the question the model is expected to answer
• the anticipated objectives
• the constraints and available data
• the performance levers to analyze

This Lean Six Sigma-based scoping ensures a useful, focused, and results-driven model.

Model Creation (within 2 weeks max)

“Quick & Approximate First Version”
We build an initial operational version of the digital twin, including:
• a complete flowchart
• active flows (agents, machines, resources)
• simplified mathematical logic
• an initial graphical user interface
• early KPIs (throughput, queue lengths, utilization rates)

Goal: rapidly bring a concrete, interactive model to life for your teams, validating system behavior and logical flows.

At the end of this stage, the model runs autonomously and already tells a story about the system.

Refinement Sprints (Flexible Duration)

After the initial version is delivered, we enter a model refinement phase to ensure accuracy and alignment with reality. During this sprint-based process we perform:
• Field calibration of process times
• Integration of real-world variabilities (breakdowns, demand variability, shared resources)
• Fine-tuning of business rules
• Adjustments to flows, capacities, and cycle times
• Enrichment of the interface and KPIs

Process:
• Weekly Agile sprints
• Weekly Steering Committee (COPIL) for validation
• Iterations until model behavior matches operational reality

Objective: Deliver a high-fidelity digital twin, fully adapted to your operational context.

Optimization Tests & Scenarios

Once the model is validated, we vary all parameters. For optimization models, we determine optimal settings using the OptQuest® algorithm (OptTek Systems)—one of the world’s leading optimization engines.
Each scenario is virtually tested before physical implementation.

Outputs are delivered in a visual, pedagogical format, accessible to both decision-makers and frontline teams.

Goal: understand dynamics, predict outcomes, and optimize performance.

Analysis, Recommendations & Capability Building

We transform simulation outputs into clear decisions:
• winning scenarios
• prioritized investments
• risks to eliminate
• target organization design
• projected ROI

Lean Art then supports your process owners and managers to anchor new practices and ensure team autonomy.

Discover our projects and contact us for a complimentary assessment