lecture 3b
Post on 15-Apr-2017
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KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
01
TOYOTA KATAHow to Correctly Write Obstacles?
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
02
Using a Well Known Challenge Game to Demonstrate Writing Obstacles
• Often, Kata Practitioners use various games and simulations to demonstrate a fast paced environment with limited resources to allow students time to practice in a relatively safe classroom environment before taking the IK/CK to actual operational situations.
• The following example is one such challenge game.• You will notice that most people start out writing short, vague phrases to
describe the obstacles keeping them from operating in the Target Condition. This is normal – everyone does this as they start practicing.
• What most students of Toyota Kata fail to see early on is that the steps of the Improvement Kata build upon each other, and the clarity of each step is dependent on the clarity of the previous step.
CurrentConditionTargetConditionObstaclesPDCAExperimentsClarity ClarityClarityClarity
KATA
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© 2016 Jidoka®
03
The TaskSet up this 200 pc domino patternas quickly as possible with 100% topple* rate.
* Domino has fallen more than 45 degrees.
25 pcs in each of
these 6 legs
50 pcs in this one leg
These Count!!!
This one doesn’t Count!!!
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
04
Many times we want to write a noun or an occurrence as an obstacle:
How to Correctly Write Obstacles to the Target Condition
OBSTACLESPARKINGLOTObstacle Howwillyoumeasure that?
1 Toppletoosoon
2 ShakyTable
3 Transitionpieces
4
5
• Vague• HardtodefineagoodPDCAStep
• Can’tmeasurethis
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05
We think we are there with more description of the occurrence:
Better to Write Facts and Data as Obstacles to the Target Condition
OBSTACLESPARKINGLOTObstacle Howwillyoumeasure that?
1 We get½builtandtopple
2Thetableisshakyandifwebumpdominostopple
3Wecan’tgettransitionpiecessetcorrectly
4
5
• Moredescriptionoftheissue
• DifficulttodefineagoodPDCAStep
• Stillcan’tmeasurethis
KATA
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© 2016 Jidoka®
06
Best to Write Facts, Data, and a Negative Result – Or - A Question Needing Answers for an Obstacles
to the Target ConditionOBSTACLESPARKINGLOTObstacle Howwillyoumeasurethat?
1
Whenwestartonthe4legsof25,twoworkersinterferewiththeworkpatternandwetopplebefore completion
Topple%,andauditofstdworkpattern100%
2
Wedon’tknowawaytopreventbumpingthetableandhavetoppledtoosoontwicein eachofthelast2attempts
Wecalloutaloud“bump”andcounthowmanytimeswebumpthetable.
3
Wedon’tknowhowmanydominostosetasidetomakethetransitionpiecesattheforksandset themcorrectly
Wecountout3dominosateachtransition
Fact+Data
NegativeresultQuestionneedinganswered
Fact+Data
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07
Examples of Poorly Written Obstacles
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After Coaching…The Learner expanded what he/she didn’t know, but still did not write the obstacles in the proper form in order to write a clear PDCA.
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09
Obstacles Written as “To Do” Action item lists – This is counter to Kata
Writinganobstacleusingverbslike“need”,“make”,or“training”aredeadgiveawaysthattheLearnerisresortingtoingrainedhabitsofactionitemlistsresultingfromepisodicimprovementevents.
TrainingisasolutionforaPDCAstep- lackofknowledgeorskillwhichisobstacle
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10
Too Many Obstacles and Written as “Blames”– This is counter to Kata
Blamingtheoperation’scurrentconstraints, factsandrequiredpracticesorjobfunctionsareexcuses andnotobstacleidentificationwhichisthekatawayofthinking.AsaKataCoachevaluateyourLearner’sThresholdofKnowledge(TOK),coachtheLearnertoexploreinnovation,andlearntospotvictim mentality,soyoucancoachLearnersthroughobstacleidentification.
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11
Obstacles Written as Statements and Phrases – How Can We Measure These?Statementsoffactwithoutthenegativeresults,trends,ortheaffectonprocessmetricswhicharecausingagapbetweenCurrentConditionandtheTargetConditionarenotobstacles.
CoachyourLearnerstoidentifythegapbetweenCurrentConditionandTargetConditionfirst,thengivethefacts+data,followedbywhattheimpactontheprocessmetrics,thesefactsarecausing.
Thisstatementcouldbeinfinite…..
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© 2016 Jidoka®
12
Obstacles Written Correctly, with a Method of Measurement
Here we have Fact+Data+ Negative result or as a question needing answered to increase or Threshold of Knowledge (TOK)
FactsanddataalongwiththenegativeoutcomeoraquestioncausingthegapbetweenCurrentConditionandTargetCondition
Factalongwiththenegativeoutcomecausingthegap
TheDataindicateshowwecanmeasurethisobstacle
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© 2016 Jidoka®
13
Obstacles Written CorrectlyHere we have Fact+Data+ Negative result or as a question needing answered to increase or Threshold of Knowledge (TOK)
ObstacleParkingLot Howwillyoumeasurethat?WehavedeterminedthatthescraplossonthemachininglineforpartsthatareproducedfromPress105resultina0.5%scraprate.ThescraplossfrompartsproducedonPresses108and115causeascraplossof3.5%-5%.Wedonotknowthereasonsforthisdifferenceinscraplossfromthesepresssources.
Theprocessmetricofpresssetupparametersandset-uptimesonPresses108and115;theoutcomemetricofScraponthemachiningline.
Fromapreviousexploratoryexperiment,werecorded112additionalpartsovera4hourproductionrunwhenwedidnotlettheshiftruncompletely"dry"ofWork-In-Processpartsbetweenshifts.Wedonotknowtheaffectthiswillhaveacross3shiftsandifdowntimeduetominorstart-uploseswilldecreaseornot.
Totaldailyproductionanddowntimerecordedinthefirst60minutesofstartofeachshift
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