We have an old pharmacy on one side of our campus, and it is time to rehabilitate it. We decided to use Lean principles in designing the new space. To do this, we pulled together a team of people, virtually anyone who touches the pharmacy or its products to look at work flows, find waste, and design a future state.
Part of that analysis is a "process failure mode effects analysis," which is basically a risk mitigation technique. Especially for a critical area like the pharmacy, you want to anticipate in advance where failures in process are likely to occur, so you can design the work flow to minimize those.
But this assignment also required a view of how the actual physical facility would work. So we used an empty floor of a neighboring building and built a full-scale mock-up using cardboard boxes and the like. Then people simulated the new work flow to keep refining the plan.
Here's a video showing some scenes from this exercise. If you can't see the video, click here.