toyota kata direct - lean frontiers · 2018-12-15 · the four steps of the improvement kata 2....

Toyota Kata Direct

Lean Frontiers, Inc. TWI Institute KataCon & TWI Summit Feb. 18-22, 2019www.leanfrontiers.com www.twi-institute.org www.leanfrontiers.com/skillsweek 1

The Four Steps of the Improvement Kata

2. Grasping the Current Condition

Sam Wagner, Director of CI and TrainingFAST Global Solutions

swagner@fastsolutions.com

Steps of the Improvement Kata

Thanks to Mike Rother

Toyota Kata Direct

Lean Frontiers, Inc. TWI Institute KataCon & TWI Summit Feb. 18-22, 2019www.leanfrontiers.com www.twi-institute.org www.leanfrontiers.com/skillsweek 2

The Linear View

Thanks to Mike Rother

WE ARE HERE!

Professional science:Making observations / recording datato illustrate what we know now

Purpose ofGrasping Our Current Condition

… and expand our knowledge threshold… and expand our knowledge threshold

…

Where we are now, what we have

1st

Target Con‐dition

Perfect

Toyota Kata Direct

Lean Frontiers, Inc. TWI Institute KataCon & TWI Summit Feb. 18-22, 2019www.leanfrontiers.com www.twi-institute.org www.leanfrontiers.com/skillsweek 3

Importance of Grasping the Current Condition

Bill Costantino’sTK Unified Field Theory

IssuesProblemsWaste

YouMe

Grasping the Current Condition at Different Levels

Thanks to Mike Rother

Toyota Kata Direct

Lean Frontiers, Inc. TWI Institute KataCon & TWI Summit Feb. 18-22, 2019www.leanfrontiers.com www.twi-institute.org www.leanfrontiers.com/skillsweek 4

Tips For Grasping the Current Condition

What?

• Current state of the measurable outcome you’re striving to achieve

• Process characteristics, including when & where in the flow it occurs

• Condition of tools and equipment

• What would the customer want to know?

• Consider both process and people

How? (and Why?)

• Be specific and quantitative, avoid generalities (so it’s clear)

• Visualize data in charts and graphs, hand-written (so it’s quick)

• Go to gemba to discover the truth, avoid assumptions (so it’s factual)

• Focus on understanding process patterns (so it’s meaningful)

Grasp the Current Condition… of the People

• How are you feeling today as a Coach?  How’s your Learner feeling today?

• Is your Learner mentally and emotionally ready to expand their Knowledge Threshold?  Are you ready to coach them there?

• How is your Learner feeling about the difficulty of reaching the Target Condition?

OK, but how do we measure these?

Toyota Kata Direct

Lean Frontiers, Inc. TWI Institute KataCon & TWI Summit Feb. 18-22, 2019www.leanfrontiers.com www.twi-institute.org www.leanfrontiers.com/skillsweek 5

Grasp the Current Condition… of the People

• How are you feeling today as a Coach?  How’s your Learner feeling today?

• Is your Learner mentally and emotionally ready to expand their Knowledge Threshold?  Are you ready to coach them there?

• How is your Learner feeling about the difficulty of reaching the Target Condition?

Quick Check‐inMeasure: 10               8              6              4               2              0

Case Study:  Learning to Weld

• Challenge:  Fill 16 chronically open welding positions within 8 weeks with certified welders

?

Toyota Kata Direct

Lean Frontiers, Inc. TWI Institute KataCon & TWI Summit Feb. 18-22, 2019www.leanfrontiers.com www.twi-institute.org www.leanfrontiers.com/skillsweek 6

Case Study:  Learning to Weld

• Challenge:  Fill 16 chronically open welding positions within 8 weeks with certified welders

Case Study:  Learning to Weld

• Challenge:  Fill 16 chronically open welding positions within 8 weeks with certified welders

!

Toyota Kata Direct

Lean Frontiers, Inc. TWI Institute KataCon & TWI Summit Feb. 18-22, 2019www.leanfrontiers.com www.twi-institute.org www.leanfrontiers.com/skillsweek 7

Just Get Going!

Go On – Take Step 2

Step 2.  Grasp the Current Condition

Prevent acting on preconceived 

notions

Expand our Knowledge Threshold

Visuals & Graphics

Measurable so you know when it improves

Process and

People

Condition NOW Why

How

What

In order to

Which is

& includes

In a way that is

Using hand‐drawnSet a good next 

Target Condition

Quick & Current

So

Toyota Kata Direct

Lean Frontiers, Inc. TWI Institute KataCon & TWI Summit Feb. 18-22, 2019www.leanfrontiers.com www.twi-institute.org www.leanfrontiers.com/skillsweek 8

15

Thanks to Bill Costantino