challenge driven improvements -through toyota kata€¦ · challenge driven improvements -through...
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Challenge Driven Improvements
-through Toyota Kata
Lean Iceland 2016Pia Anhede, Revere AB
CurrentCondition
TargetCondition
Test!
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Revere AB
BOOKS
CONSULTINGIndustri, healthcareservice, media, mm>15 countries, > 20years
Pia Anhede, MScJoakim Hillberg, MSc/MBA
ACTION LEARNINGProductionService/ admin Healthcare
c/o Chalmers, Hugo Grauers Gata 3, 411
33 Göteborg, Sweden,
Mobile +46 705 43 80 48
NETWORK
TRAINING, MASTER MEETINGS & CERTIFCATION.
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The Improvement Kata
The research behind
Challenge driven improvements
5-Sep-16
3
The research by Mike Rother that led to the book Toyota Kata ran from 2004-2009.
The research was guided by these two questions:
1. What are the unseen managerial routines and thinking that lie behind Toyota’s success with continuous improvement and agility?
2. How can other companies develop similar routines and thinking in their organizations?
VisionNext
TargetCondition
CurrentCondition Obstacles Challenge
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Research and understanding about lean
5-Sep-16
4
Gen 1 Methods and toolsValue stream mapping, 5S,
kanban, …
Gen 2 Leadership and principles Likers 14 management principles
Spear Decoding the DNA of Toyota…
Gen 3 Behaviours and routinesImprovement kata
Gen 4 ??
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Focus with kata
5
Visible
LessVisible
Tools and techniques to improve quality, cost and delivery
• A systematic, scientific way of thinking and acting
• Managers as trainers
What changes an organization’s behaviour to continuous improvement towards the strategic challenges!
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Kata – a pattern of scientific thinking and
systematic improvements beyond what we
can, do and know today.
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READ WHAT YOU SEE
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Our amazing brainfilled in the blanks!
READ WHAT YOU SEE
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Read what you see
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But our brain automatically filled in the blanks here too, instead of saying “Sorry, I don’t know yet”
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It can be wrong
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Current knowledge threshold
Our brain automatically fills in the blanks
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This cognitive mechanism helps
us get through the day
But it also causes problemsWe often don't notice our Knowledge Thresholds.
We feel quite sure and make faulty decisions.
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Born?
ScientificThinking
We are notoriously bad at scientific thinking, due to natural, unconscious mental mechanisms
Learn through training
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Improvement kata & Coaching kata
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JI/2016-05-09
Internal
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Agenda
► Intro to the Tetra Pak case
► Agree the difference (challenge)
► Do it different (improvement kata)
► Be the difference (coaching kata)
JI/2016-05-09
Internal
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Brand Management/2016-04-14
We specialise in providing customers with complete solutions
for the processing, packaging and distribution of food products
Focused on our customers
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Brand Management/2016-04-14
Present in more than 170 countries and operations in all continents
Brand Management/2016
80 sales offices
32 market companies
6 R&D units
11 Technical Training Centres
48 manufacturing sites
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Total world deliveries 2015
Brand Management/2016-04-14
Carton packaging material, billions of packs
184Distribution machines
1,047
Packaging machines
411
Processing units
2,118
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Tetra Pak in summary, January 2016
Brand Management/2016-04-14
► Employees: 23,600
► Net sales billion €: 11,9
► Countries where Tetra Pak®
packages are available: >170
► Packaging material and closure plants: 37
► Filling machine assembly plants: 5
► R&D units: 6
► Technical training centres: 11
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Intro to the Tetra Pak case
► Spread continuous improvements to the full company
− Well-established in our supply chain
− Improve through eradication of losses
► What trigger and motivate the continuous improvements in
our part of the company?
− Packaging Material development, about 200 employees
− Long cyclic & none repetitive work, e.g. five-year technology
development projects
JI/2016-05-09
Internal
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About me
► Manager for the project management office and responsible
for driving the continuous improvement work for Tetra Pak’s
global package material development
► 12 years’ experience in driving continuous improvements, e.g.
as Lean Six Sigma Black Belt at Alfa Laval and in many
different departments of Tetra Pak, such as World Class
Manufacturing Champion in the supply chain and as senior
analyst
► Quality manager in a global quality initiative across the full
company
► Today working within the development organisation to
improve their organisational capability to deliver towards its
strategic objectives by using challenge driven improvements
JI/2016-05-09
Internal
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Agree the challenge
► Management ownership
− Set by management
− Clear direction & scope (focus areas)
► Communicated
− All mangers involved in setting it
− Communicated to all
► Concrete & measurable
JI/2016-05-09
Internal
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Do it different (improvement kata)
► Losses vs challenge
− To reach the full year challenge
− Key for our technology
leadership & part of our balance
scorecard
► Concrete & time set
− Bi-monthly target conditions
− Action list vs experiment log
► Learning loops & creativity
JI/2016-05-09
Internal
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Be the difference (coaching kata)
► It’s all about the daily behaviors
− 25% direct involvement
− Change in the managers role
► Coaching principles for management
− The coach owns the result and the challenge
− Coach do not gives solutions, focus on the improvement capability
− Support frequent experiments and learning from them
► 2nd coach
− To make it stick these principles needs to be
applied daily by management
JI/2016-05-09
Internal
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Our status
► Clear challenge & consistent scope
− Keep our focus for the full year
− Sharpen the scope even further next year & quantify the
challenge
► Measureable results
− Visualizing & quantifying the improvement results
− Ask about the results
► Strong improvement culture
− Persistent leadership, apply the coaching principles frequently
− 2nd coach support to the improvement and coaching capability
JI/2016-05-09
Internal
Challenge driven improvements (Kata)
Con
cre
ten
ess &
fre
qu
en
cy
Challenge
Experiments
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Mål-
tillstånd
Nuvarande
tillstånd Co
ach
kort
Iterate Toward the Target Condition
Daily coaching
CC
TC
Reflect on the Last Step
Because you donʼt actually know
what the result of a step will be!
1) What was your Last Step?
2) What did you Expect?
3) What Actually Happened?
4) What did you Learn?
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There are always a knowledge threshold
If we just ignore the knowledge threshold, make an activity list and start to execute, instead of experiment and learn, the problems
arise!
Action plan
False security
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The three core roles for daily
practicing
Improvement kata
Process and team
Story-board
Focus here is developing coaching ability
Focus here is developing improvement kata routine
Coaching
kataLearner
(team leader)
2nd Coach
Participates periodically
Pays particular attention to the Coach (coaches the Coach)
Coach(Manager)
The Coach is responsible for teaching the Improvement
Kata pattern, and for the results
The Coach uses the CoachingKata, asking the 5 CK questions
The team ownsthe target condition
and works to achieve it
The Learner & team applythe Improvement Kata
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How do we focus behaviours and not
implement kata as a new tool or
method?
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2016-09-05
Titel
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