kata in newport news, virginia an approach to coaching and...

2/18/2016

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Kata in Newport News, Virginia

An Approach to Coaching and Teaching at All Levels

www.continental-corporation.com Powertrain Division

Public

› Leadership Training

› Leadership skill development

› Advanced Team Meetings

› “What” and “How”

› Coach 2 Training (Coach Development Process)

› How the game is played and how we keep score

› Kata in Everything We Do

› Beyond the Kata boards

Kata Landscape at Continental Newport News

18 February 2016

2 D. Kilgore, © Continental AG

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Public

18 February 2016

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Entropy

Large

Projects/Events

Tools for “Small” CI:

TPM Tags

OPL

5S

Six Sigma

Kata

Current

State

Future

State

Small CI projects every day

+

Culture

change

CI mindset

and behavior

D. Kilgore, © Continental AG

Kata at Continental Newport News Back Story

Public

Kata at Continental Newport News Never Give Up!

18 February 2016


› No preparation

› Dictated to us

› Negative attitudes

› We taught “how”

Failed Attempt 1 (Q2, 2013)

› Preparation – read the book

› Positive people

› Wanted to succeed

› We taught “how”

Failed Attempt 2 (Q3, 2013)

› Preparation – read the book

› Positive people

› Wanted to succeed

› We taught “why” first, then “how”

Successful Attempt 3 (Q3,2014)

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Public

Kata at Continental Newport News Back Story – Why?

18 February 2016


We will provide our customers with

the best precision automotive

components through a relentless

pursuit of quality and operational

excellence, and through continuous

improvement in everything we do.

NPN Plant Vision

Create an environment that allows

our team members to thrive and

develop.

5th Strategic Thrust

Leadership

› Engage 600 people to

make the best

decisions they can

every day.

Reference: David Marquet – Ladder of Leadership

Public

Kata at Continental Newport News Back Story – How!

18 February 2016


We will provide our customers with

the best precision automotive

components through a relentless

pursuit of quality and operational

excellence, and through continuous


NPN Plant Vision

Create an environment that allows

our team members to thrive and

develop.

5th Strategic Thrust

Leadership

› Engage 600

people to make the

best decisions they

can every day.

Kata

› Sustainability through CI

every day by every person

› Coaching and teaching at

all levels


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Advanced Team

www.continental-corporation.com ES, Powertrain

Team Members

› Alex Delgado

› Dave Kilgore

› Jorge Padilla

› Kevin Francis

› Andrew Turner

› Giuseppe Latorrata

› Jan Bennett

› Garry Reedy

› Jennipher Allison

› John Miller

› Dave Rogers

› Chris Connor

› Justin Shank

› Kimberlie Shumaker

› Tiffany Burton

› Albert Kaiser

› Steven Leach

› Marcelo Correa

› Seth Shumaker

Sr. Engineer

Plant Manager

Sr. Engineer

Sr. Engineer

Logistics Specialist

Plant IE Manager

Engineering Analyst

Quality Analyst

Value Stream Manager


Maintenance Coach

Logistics Manager

Project Manager

Production Coach

SCE Team Leader

Focus Factory Manager

Quality Manager



Public

Kata at Continental Newport News Advanced Team

18 February 2016


We will provide our customers ….

continuous improvement in

everything we do.

NPN Plant Vision

Create an environment that allows our team

members to thrive and develop.

5th strategic Thrust

AT Kata Improvement Board

Create an environment that allows our

team members to thrive and develop

through coaching and continuous


AT Kata Challenge

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Public

Advanced Team Kata Board and Meeting Structure

18 February 2016


Meeting format › Weekly meeting - one hour long

› First half – coaching session with process owner (learner) and plant manager as (coach)

› Rest of team provide Coach 2 feedback

› Second half – coaching session with a selected practicing Kata board (Status on Nov. 2015)

Meeting intent

› Using Kata to guide deployment efforts

› Open forum for coaching and teaching

our leaders

› Coaching skill development

Public

Kata at Continental Newport News Advanced Team

18 February 2016


› Internal training curriculum

› Selection of next Kata consultant

› Recommendation for leadership training –

“Why Kata”

› Guidelines for consistent board content

and discipline.

› Coaching skill development – Coach 1

and Coach 2

› Coaching in everything we do

› Cascading boards

Outcomes

AT Kata Improvement Board

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2nd Coaching Coach Development Process

Public

The 2nd Coach Process 13 Attributes – Process Metrics

18 February 2016

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Kata board tells the story Challenge relates to business goals Target condition relates to challenge Target Condition Depicts Gap Target Condition has "achieved by" date Current Condition Updated Written = What is said Last step documented on PDCA record Obstacles discussion Next Step written down and sized Next Step addresses the "one obstacle" Next Step has predicted outcome Coach sticks to 5Q Sequence

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Public

The 2nd Coach Process Process Metrics and Outcome Metrics

18 February 2016

13 D. Kilgore © Continental AG

Discuss what attributes to

focus on prior to coaching

session – “Target

Condition”

1

Observe and assess 13

attributes – “Current

Condition”

2

3

Process Description Kata board tells the story

Challenge relates to business goals

Target condition relates to challenge

Target Condition Depicts Gap

Target Condition has "achieved by" date

Current Condition Updated

Written = What is said

Last step documented on PDCA record

Obstacles discussion

Next Step written down and sized

Next Step addresses the "one obstacle"

Next Step has predicted outcome

Coach sticks to 5Q Sequence

Attributes

The data we

collect in the

Coach 2 process

becomes the

Current Condition

for the Advanced

Team! Provide immediate

feedback on 1 or 2

attributes: “Learning” and

“Next Step”

PDCA

Public

› Populated with data from coaching assessment sheets

› Current condition of all active Kata boards

The 2nd Coach Process

18 February 2016

14 Author, © Continental AG

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Public

The 2nd Coach Process and AT Target Conditions

18 February 2016


Create an environment that allows our

team members to thrive and develop

through coaching and continuous


AT Kata Challenge




KATA in Everything We Do Beyond the Kata Boards

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Public

Playing the Game What is Happening Daily?

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D. Kilgore © Continental AG

› Coaching through standard

questions

› Focus on the “Process”

rather than KPI

› Focus on specific issues one step at a time

› 100% Transparency – follows the Coaching Kata

Production Product Management (PPM) Fast Response – customer logistic issues

› Time efficiency – reduced from 1 hr. to 20 min.

› Set-up expectations of next steps and follow-up

› Coaching Champions

through standard questions

about 5S

› Focus on the “Process” of

improving the lowest rated

item rather than the Self

Assessment Score

Public

Language of responsibility

› Language used during conversations

› Key words you hear as a leader or coach – “ladder of leadership”

What is the behavior?

› Managers and leaders have shifted discussion mechanisms – “obstacles and next steps”

› Management behavior – focus shifted from management by KPI to management by process

› Peoples’ attitudes towards continuous improvement – “my next step is….”

Kata in Everything We Do The Culture is Changing…How Can We Tell?

18 February 2016



Tell me what to do…

I request permission to…

I recommend…

I think…

I have done…

I intend to…

I have been doing…

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Public

Our Challenge, Current Condition and Obstacles are different than yours

What’s your next step?

18 February 2016


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