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When I got involved in MLR as an investor I was determined to bring some of the great business simulation can to the MLR, and The Hat Factory was always going to be first. I feel like a  kid being with MLR, it is like founding some of my favourite toys that I haven’t seen it a while all safely boxed up in the attic. This brilliant business simulation had been my secret weapon for years, and now it's back where it belongs.

The Magic Moment That Started It All

Picture this: Manchester, 2018. I'm standing in front of thirty middle managers from a construction firm, and they're giving me that look. You know the one – the "here we go again with another boring training session" expression. These were tough cookies who'd seen every management fad come and go.

Then I introduced The Hat Factory.

Within minutes, the room transformed. These hardened site managers were suddenly huddled around tables, frantically folding paper into Sailor hats and Princess cones, arguing over production schedules like their bonuses depended on it. Which, in the simulation, they did!

Why The Hat Factory Works When Others Don't

What makes this simulation special isn't just the paper folding – though watching a quantity surveyor discover he's hopeless at making Drummer Boy hats is always entertaining. It's the layers of real business challenges that unfold naturally.

The teams start confident. "How hard can it be to make paper hats?" they think. Then the orders start flowing in. Regular customers need their deliveries on time. New customers appear with rush orders. The cutting machine breaks down (we literally take away their scissors). Someone goes on holiday. Overtime costs money.

Suddenly, they're facing every production nightmare you can imagine – capacity planning, quality control, resource allocation, cost management. All while racing against the clock with coloured paper and tape dispensers.

The Learning That Sticks

In that Manchester session, I watched something beautiful happen. The finance director, who'd been quietly sceptical, suddenly understood why production delays cascade through the business. The operations manager realised why his team got frustrated when priorities kept changing. The HR director saw firsthand how one person being off sick could derail everything.

But here's the kicker – they learned it themselves. I didn't lecture them about production planning or resource management. They discovered it through making mistakes, solving problems, and feeling the pressure of competing teams breathing down their necks.

The Debrief That Changes Everything

The real magic happens in the debrief. When teams compare their strategies, the insights pour out. Why did Team A focus on high-value orders while Team B tried to please everyone? How did Team C manage to work around the equipment breakdown so smoothly? What would they do differently next time?

These aren't theoretical discussions. They're talking about decisions they made under pressure, mistakes that cost them money, and successes they earned through teamwork and quick thinking.

Why I Missed It So Much

For a few years, The Hat Factory disappeared from the MLR catalogue, and I felt the loss keenly. I tried other simulations, but nothing quite captured that perfect blend of simplicity and complexity. Nothing else got people so quickly invested in the outcome.

Other business games can be too abstract or too complicated. The Hat Factory hits the sweet spot – anyone can understand making paper hats, but the business challenges are absolutely real. It's accessible without being simplistic, engaging without being frivolous.

The Trainer's Best Friend

From a facilitation perspective, the Hat Factory is a dream. The instructions are crystal clear. The materials are simple but effective. The timing works perfectly – just long enough to build pressure without losing momentum.

I love how it handles different group sizes effortlessly. Whether you've got twelve people or twenty, the competition between "factories" creates natural energy. Everyone gets involved because everyone has a role to play.

And the discussions it generates! I've seen quiet team members suddenly become vocal advocates for better planning. I've watched senior executives admit they underestimated the complexity of operational management. It breaks down barriers and gets people talking honestly about real workplace challenges.

Back Where It Belongs

Now that the Hat Factory is back on the MLR site, I'm already planning where to use it next. That leadership programme in Birmingham? Perfect. The team development session for the manufacturing client? Ideal. The management development course that's been lacking that special something? Problem solved.

There's something deeply satisfying about having a training tool you can rely on completely. The Hat Factory never lets you down. It engages every personality type, works across industries, and delivers insights that participants remember months later.

The Real Business Impact

The best part? The learning transfers beautifully to the real world. That construction firm from Manchester? Six months later, their project delivery times had improved by 20%. Coincidence? I don't think so.

When people experience the frustration of poor planning and the satisfaction of smooth operations firsthand, they carry those lessons back to their desks. They think differently about resource allocation, communicate better about priorities, and understand why operational excellence matters.

The Hat Factory isn't just a training exercise – it's a catalyst for better business thinking. And now it's back where ambitious trainers can get their hands on it.

Welcome home, old friend. I've missed you.

The Hat Factory Complete Kit is available now: SHOW ME. Perfect for management development, team building, and operations training programmes.