Thinking win-Win-WIN !!

Kata Summit, Fort Lauderdale, Fl February 18, 2015

Improvement Kata Experience

Participant Notes

Improvement Kata content by Mike Rother Instructional Design by Bill Costantino, W3 Group Version 8.0

TKE Training by

W3 Group is dedicated to developing and delivering high impact, skill-based, training on all aspects of Toyota Kata.

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Courses Initial coached practice

AWARENESS SKILL BUILDING

Read a Book, Article

IK Seminar (1-Day)

IK Experience (1-Day)

Online Materials

Conference Presentation

On-Site Practice (2-days)

3-Day Custom Course

at your site (Form Adv Group)

Be a repeat host site

Active Support Regular practice

On Your Own Daily practice

Frequent / Daily Coached

Practice External Master Coach support for

Advance Group

LinkedIn TKLN Group

Video remote coaching

Consortium MEP

Breakout Session

Seminars & Info Self service

IK Learning Roadmap

Practitioner Day (1-Day)

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Intended Outcomes

• Understand the basic

routines of Toyota Kata

via direct experience.

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• Directly experience the power and value of rapid PDCA and Coaching Cycles through repeated practice

© Mike Rother

The Pattern of the Improvement Kata

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Another Way to Look at it.

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Distant “True North” 1-3 years

1 week – 3 months

Often Vague “Principles” Concrete

Hard Metrics Successive T/Cs to achieve the

Challenge © Mike Rother 8

Challenge Examples

• $3.3M inventory reduction

• 95% OTIF (On Time, In Full Delivery)

• 50% of volume produced through contract suppliers

• Procurement savings $750,000

• 12% productivity improvement with existing resources.

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Challenge creates alignment between different functions / departments

toward a Shared Objective

© Mike Rother

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Your current pattern of working for the first 2 rounds.

© Mike Rother

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a

b

c

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a a

b

c

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Not enough time for process metric

in 4 hours!

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( By Round #___ )

How the game is played.

What’s the score

4 Categories of Information

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Often, these are decided from the

“Bottom Up” First

Next

Next

Next

© Mike Rother

The Roles

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Manager Supervisor

Supervisor Owns the Target Condition.

Manager Advises and Supports

© Mike Rother

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What it Actually Looks Like! Common Idea of PDCA

© Mike Rother

What it Actually Looks Like!

© Mike Rother

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Current Condition

Target Condition

The path will be unclear.

Obstacles

Unclear territory

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? ?

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? ?

? ?

? ?

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Rapid PDCA toward T/C

Small, rapid experiments advance our knowledge quickly

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B A

C

Each Row = One Experiment

• To Happen • To Learn

© Mike Rother

Single Factor Experiment

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C O

A C

H I

N G

K

A T

A The Five Questions

1) What is the Target Condition?

2) What is the Actual Condition now?

----------------- Turn Card Over ------------------>

3) What Obstacles do you think are preventing

you from reaching the target condition?

Which One are you addressing now?

4) What is your Next Step (next Experiment)

What do you Expect?

5) How quickly can we go and see what we

have learned from taking that step?

First Coaching Cycle

© Mike Rother

C O

A C

H I

N G

K

A T

A The Five Questions

1) What is the Target Condition?

2) What is the Actual Condition now?

----------------- Turn Card Over ------------------>

3) What Obstacles do you think are preventing

you from reaching the target condition?

Which One are you addressing now?

4) What is your Next Step (next Experiment)

What do you Expect?

5) How quickly can we go and see what we

have learned from taking that step?

© Mike Rother

Reflect on the Last Step Taken

1) What did you plan as your Last Step?

2) What did you Expect?

3) What Actually Happened?

4) What did you Learn?

Return to question 3--------->

Because you don’t actually know what the result of a step will be!

-------- Turn Card Over --------

Second Cycle and Beyond

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Learner

2nd Coach (not always

present)

Record of PDCA Cycles

Coach

Your Turn…!!

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Listen when language becomes vague or uncertain: I think… It probably… Well…?? Most likely…

This is the time to take a step forward with the next PDCA. This is the LEARNING EDGE.

© Mike Rother

Apparent Certainty

Uncertainty

Mystery

Green Zone: Comfortable

Familiar Predictable

Easy Confidence

Threshold of Knowledge

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Next Target Condition Learning Zone:

Uncertainty Trial & Error

Discovery Learning

Innovation

Threshold of Knowledge

Our Intent Today…

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• To demonstrate

the core routines

of TK,

• allow you to

compare to your

current way of

working.

• try to get the

“pattern” of working

• give you something

to think about and…

© Mike Rother

What are we really doing here? • Practicing patterns, IK / CK, rigidly at first… so they

become deeply ingrained… so that they become automatic / reflexive - No longer requiring your conscious attention

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1

© Mike Rother

Practicing to become more comfortable in the Learning Zone

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Apparent Certainty

Uncertainty

Mystery

Comfort Zone

Learning Zone

Comfort Area

Expanded

Evaluations

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