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Optimization Through Toyota Kata
Jeff Fuchs,
Neovista
Consulting,
MD World Class
Consortia
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© 20142
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Toyota Kata
“Mike
Rother,
you have
ruined
my life.”
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What Lean Is:
Involving All Employees/Leaders
Continuous Improvement Habits
Cycles of Improving/Learning
↑Customer Value, ↓Waste
Every Day
Systematically
Solving Problems
Everybody
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Kaizen
“A small change for the better”
Continuous improvement
“How lean gets done”
“Kaizen Event”, “Kaizen Blitz”, “Rapid Improvement Event”:
Generally conducted by cross-functional teams
Tightly focused, largely completed in a week
Historically, the foundation of Western lean improvement
A stepwise, “improve + sustain” improvement pattern
Can create gaps, lost momentum, missed opportunities
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Kaizen at All Scales
“Just Do It”
Daily Kaizen
Continuous
Improvement
Hours, DaysPrj
Events
JDI / CI
Kaizen Events
Rapid Improvement
Events
Days, Weeks,
Months
Transformational
Lean Projects
Months, Years
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Kata: The Invisible Parts of Lean
Kata explains many of the knowledge shortfalls
and application gaps of TPS/Lean:
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WHAT ARE KATA?They're practice routines. Kata are structured routines to practice deliberately, especially at the beginning, so their
pattern becomes a habit and leaves you with new abilities
KATA:
• Are for learning fundamentals to build on.
• Are a way of transferring skills and developing shared abilities and mindset in a team or organization.
“Let’s begin by practicing it this way for a while.”
By Mike Rother 7
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This Is Kata…
Skills are not innate: You are not just “born with it.”
Many results come from habits people have learned through practice, deliberate or not.
What are some of the deliberate and “mindful-less” habits you see in your business and personal life?
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…And This Is Kata
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The Improvement Kata and Coaching Kataare Practiced to Develop Scientific Mindset
WHAT KATA ARE FOR
Beginners should follow Kata exactly; not deviating from them, so the Learner can internalize the patterns. But with increasing proficiency each Learner can start to (within limits) develop their own style.
Likewise, over time each organization can evolve the Kata it began with to better suit and mesh with its culture. The original Kata evolve into organization-specific practice routines.
By Mike Rother 10
KataPractice
To develop foundational
skill and mindset
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THEIMPROVEMENT KATA
The Coaching Kata is a pattern for managers to follow in teaching the Improvement Kata pattern in daily work, so that it becomes part of an organization's culture.
The Improvement Kata is a model of the human creative process. It’s a 4-step pattern of establishing target conditions and then working iteratively (scientifically) through obstacles, by learning from them and adapting based on what's being learned.
THE COACHING KATA
By Mike Rother 11
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QUICK DEFINITIONS
By Mike Rother 12
The Improvement Kata is a set of practice routines for learning to work scientifically when you pursue goals in complex systems.
The Improvement Kata is a teachable four-step model of the scientific way of thinking & acting.
The Coaching Kata is a practice routine for how to teach the Improvement Kata pattern.
The Coaching Kata is a pattern for teaching the Improvement Kata.
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(Manager)
THE IMPROVEMENT KATA+ THE COACHING KATA
It’s a management system for developing peopleto meet challenges
By Mike Rother 13
ImprovementKata
CoachingKata
Understand the
Direction orChallenge
Grasp the Current
Condition
Establish the Next
Target Condition
IterateToward the
Target Condition
‘Executing’Coaching
Cycles‘Planning’ Coaching Cycles
Learner
Coach
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© 201414
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The Four Improvement Kata Steps
The improvement kata is the kaizen kata
A universal pattern for improving, adapting, innovating
1. In consideration of a vision or challenge setting direction…
2. …Grasp the current condition.
3. Define the next target condition.
4. Move toward that target condition with PDCA, which
uncovers obstacles that need to be worked on.
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The Improvement Kata Pattern
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1. Understand the Direction or Challenge
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1. Understand the Direction or Challenge
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2. Grasp the Current Condition
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3. Establish the Next Target Condition
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Now There’s a Grey Zone
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4. PDCA Toward the Next Target Condition
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That Brings You Here:
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Repeat the Pattern
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Notice the Difference:
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Popcorn vs. Purpose
Just “eliminating waste” doesn’t involve striving
toward something
Troubleshooting and “popcorn kaizen” vs.
purposeful striving toward a future condition
Note the different psychologies:
We moved the blow-off hose closer to the operator, which
got us a step closer to our process target condition.
We moved the blow-off hose closer to the operator, which
eliminated some waste.
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© 201426
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Teamwork and Empowerment
Better teamwork through aligned purpose
Leading with Humility
The State vs. The Act of Empowerment
My idea versus your idea… What do we need to work on next to reach
our objective?
…Or versus your idea.
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The scientific process helps you find the path not by telling you what's ahead.
It only confirms or refutesthe results of experiments.
Since the path to a challenging goal cannot be predicted with exactness, we have to find that path by experimenting like a scientist. With each insight a scientist adjusts his/her course to take advantage of what has just been learned.
THE IMPROVEMENT KATA PATTERNIS A SCIENTIFIC APPROACH
One trick to making effective progress toward a goal is not to try to decide the way forward, but to have your team iterateits way forward by experimenting as cheaply and rapidly as possible. This is the action of innovation and it can be taught.
By Mike Rother 27
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PREDICTIONTestable
ACTIONConduct theexperiment
EVALUATEInterpret theevidence
EVIDENCECollect facts and data
The scientific process of acquiring knowledge
PLAN
DO
1
23
4
CHECK(Study)
ACT
By Mike Rother 28
THE SCIENTIFIC LEARNING CYCLE
This cycle of iteration is often called"Plan-Do-Check-Act" or
"Plan-Do-Study-Act"
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What weexpect
to happen
Whatactually
happened
By Mike Rother 29
Learning
THE CORE DYNAMICOF SCIENTIFIC THINKING
This is the dynamic that allows us to reach challenging new goals through unclear territory
When experimenting is done right, small failures often provide new insight that advance your design!
“If the result confirms the hypothesis, then you've made a measurement. If the result is contrary to the hypothesis, then you've made a discovery."
~ Enrico Fermi
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THERE'S A THRESHOLD OF KNOWLEDGEBETWEEN YOU AND YOUR GOAL
It's the point at which you have no facts or dataand start guessing, and it's closer than you think
By Mike Rother 30
Any human endeavor involves a scientific process of testingand possibly adjusting. Why? Because you never knowfor sure how you are going to get there until you get there.
Predictable Zone
Current Knowledge Threshold
Next Target
Condition
Unpredictable / Learning Zone
?
We wantto be here
next
?
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NextTarget
Condition(date)
Uncertainty / Learning Zone
Where youwant to be
next
Your CurrentKnowledgeThreshold
Condition
Now?
??
WHAT SHOULD YOU DO AT THETHRESHOLD OF KNOWLEDGE?
1) Acknowledge it. (Difficult to do, until you get into the habit.)Key realization: There's always a threshold of knowledge.
2) Stop and see further by conducting an experiment. Don't deliberate over answers. Deliberate over the next experiment.
By Mike Rother 31
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NextTarget
Condition(date)
Where youwant to be
next
Your CurrentKnowledgeThreshold
Where you are now
By Mike Rother
The Scientific ApproachSMALL, RAPID EXPERIMENTS
ADVANCE OUR KNOWLEDGE QUICKLY
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Neuroplasticity: How People Learn
https://www.youtube.com/watch?v=ELpfYCZa87g
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‘Continuous’ means many minds engaged in improving their processes, and daily cycles of experimentation.
Yet our existing work routines rarely include improvement.
Systematically and scientifically improving processes is a complexskill set we are not naturally good at!
We can learn systematic, scientific improvement through deliberate practice of the
Improvement Kata routines
WHY KATA FORCONTINUOUS IMPROVEMENT?
By Mike Rother 34
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The Learner’s Storyboard
Use this format to
make kata-based
improvement visible:
Learners can use it
easily
A consistent,
repeatable basis
can be established
The Coach can see
a Learner’s thinking
clearly
The Coach can
apply the Coaching
Kata consistently
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The Five Coaching Kata Questions andthe PDCA Cycles Record are used together
Used by the Coach Used by the Learner
5-Question Coaching Dialog Rapid PDCA Cycles
By Mike Rother 37
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ASK THE FIVE QUESTIONS AT EACH STEP
By Mike Rother 38
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A Kata Coaching Cycle Example
https://www.youtube.com/watch?v=ySdYX4cNPsQ
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Clothing Catalog Kata Case
https://www.youtube.com/watch?v=6EHo4KrRKbQ
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Toyota Kata and You
Toyota Kata:
Universally applicable and practical
The heart of the Toyota Production System
Complement to cross-functional, larger-scale,
kaizen event-centered lean improvements
Gets you quickly toward “Everybody, every day,
systematically solving problems”
Builds CI habits, culture, and capabilities
Learn more through the book, website, workshops
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By Mike Rother 42
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Neovista Consulting, LLC1752 Allerford Drive
Hanover, MD 21076
www.NeovistaConsulting.net
Jeff Fuchs
President
Mobile: (443) 865-2198
Twitter: @JBFuchs