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- 1. Lean Management Teachers Practice Proces Analysis Mini Kata More OftenIdeas building on Mike Rothers work using recent experience with beginning practitioners. March 2012 Emiel van Est
- 2. Improvement Kata & Coaching Kata We practice the Improvement Kata & Coaching Kata as outlined in Mike Rothers Book Toyota Kata and the companion Handbook © Lean Management Teachers 2
- 3. WHAT INFORMATION IS IN A TARGET CONDITION?We notice these tables condition describes how youcommon. A target have a lot in want a process to operate • A target condition for a manufacturing process should include Can we standardize?of information.how to get there. the following four categories • No verbs in a target condition. Thatʼ for s • You must include a target date for achieving the target condition.Customer Demand and Line Pace• Customer takt Achieve-By Date: (required)• Planned cycle time• Number of shifts currently running (1) DESCRIBE PROCESS STEPS, SEQUENCE & TIMES A pattern you can draw or chart (see example)Overview of the Process• Define the start & end points of the process (2) OTHER PROCESS CHARACTERISTICS• Get to know the process by sketching a block diagram of it Examples: • Number of operators - Where does WIP accumulate? Used for • Number of shifts• How much does process output fluctuate? (Cycle-to-cycle and shift-to-shift) improving • Where 1x1 flow is planned, and where standard WIP• Note other details about the current operating pattern (incl. quantity) is to be located • Leveling sequenceMachine Capacity (3) PROCESS METRIC(S) (Measurement in the moment)• Can the automatic equipment support the planned cycle time?• How close are we to our current machine capacity limit? No Yes For checking process condition in real time• What is the fastest Pc/t the equipment can currently support? Examples: • Time for each step, piece, pitch, etc.• Shift options? • Degree of time fluctuation from cycle to cycleProcess Fluctuation (4) OUTCOME METRIC(S)• Time 20-40 full cycles of each operatorʼ work s No Yes• Are each operatorʼ work steps the same from cycle to cycle? s Used to To check outcome of improvement efforts check Examples: • Number of pieces per hour or shift • Leveling sequence attainment Process: outcomesNecessary Number of Operators (if process were Challenge: stable) • Productivity TC date: Theme of this TC:• Calculate number of operators Step 1: Step 2: Fill in what you will keep Fill in current © Improvement Kata Handbook Current Target the same Target Condition 11 condition data Condition Condition Step 3: Fill in what you want to change Takt time: Takt time: Pc/t: Pc/t: # of Shifts: # of Shifts: Overtime (how much): Overtime: Output / Shift (run chart): Output / Shift: # of Operators: # of Operators: Where 1x1, where WIP: Where 1x1, where WIP: Describe the process Describe the process steps, sequence, times: steps, sequence, times: Exit cycle fluctuation %: Exit cycle fluctuation %: Other observations about the current pattern: Process Metric: Outcome Metric: © Improvement Kata Handbook Target Condition 23 © Lean Management Teachers 3
- 4. This can be a generic format for the Process Analysis Mini Kata Manufacturing Processes Other ProcessesCustomer Demand and Line Pace Customer Demand and Line PaceTarget Output per day (1)Number of shiftsTakt timePlanned Cycle TImeOverview of the Process Overview of the ProcessSee drawing for steps; sequence and times Number of operators Where Work In Process Where 1x1 flowSee run chart for output cycle fluctuation (2)Machine Capacity Machine CapacityCan automatic equipment support the planned cycle time?Process Fluctuation Process FluctuationSee run chart for operator cycle fluctuationAre operators work steps the same form cycle to cycle?Necessary Number of Operators if process were stable Necessary Number of Operators if process were stableNecessary Number of Operators © Lean Management Teachers 4
- 5. We can use this Mini Kata in many phasesCustomer Demand and Line Pace Customer Demand and Line PaceOverview of the Process Overview of the ProcessMachine Capacity Machine CapacityProcess Fluctuation Process FluctuationNecessary Number of Operators if process were stable Necessary Number of Operators if process were stable Customer Demand and Line Pace Overview of the Process Machine Capacity Process Fluctuation Necessary Number of Operators if process were stable Customer Demand and Line Pace Overview of the Process Machine Capacity Process Fluctuation Necessary Number of Operators if process were stable Customer Demand and Line Pace Overview of the Process Machine Capacity Process Fluctuation Necessary Number of Operators if process were stable © Lean Management Teachers 5
- 6. Mini Kata in Target Condition Form ManufacturingProcess: Challenge: TC date: Theme of this TC: Step 1: Step 2: Fill in what you will keep Fill in current Current Target condition data the same Condition Condition Step 3: Fill in what you want to change Customer Demand and Line Pace Customer Demand and Line Pace Target Output per day (1) Target Output per day (1) Number of shifts Number of shifts Takt time Takt time Planned Cycle TIme Planned Cycle TIme Overview of the Process Overview of the Process See drawing for steps; sequence and times See drawing for steps; sequence and times Number of operators Number of operators Where Work In Process Where Work In Process Where 1x1 flow Where 1x1 flow See run chart for output cycle fluctuation (2) See run chart for output cycle fluctuation (2) Machine Capacity Machine Capacity Can automatic equipment support the planned cycle time? Can automatic equipment support the planned cycle time? Process Fluctuation Process Fluctuation See run chart for operator cycle fluctuation See run chart for operator cycle fluctuation Are operators work steps the same form cycle to cycle? Are operators work steps the same form cycle to cycle? Necessary Number of Operators if process were stable Necessary Number of Operators if process were stable Necessary Number of Operators Necessary Number of Operators Process Metric (2): Outcome Metric (1): © Lean Management Teachers 6
- 7. Mini Kata in Target Condition Form Other ProcessesProcess: Challenge: TC date: Theme of this TC: Step 1: Step 2: Fill in what you will keep Fill in current Current Target condition data the same Condition Condition Step 3: Fill in what you want to change Customer Demand and Line Pace Customer Demand and Line Pace Overview of the Process Overview of the Process Machine Capacity Machine Capacity Process Fluctuation Process Fluctuation Necessary Number of Operators if process were stable Necessary Number of Operators if process were stable Process Metric (2): Outcome Metric (1): © Lean Management Teachers 7
- 8. So, we can practice this Mini Kata twice during every coaching cycle! Customer Demand and Line Pace Overview of the Process Machine Capacity Process Fluctuation Necessary Number of Operators if process were stable Customer Demand and Line Pace Overview of the Process Machine Capacity Process Fluctuation Necessary Number of Operators if process were stable © Lean Management Teachers 8
- 9. Lean Management Teachers What do you think?Is this an improvement? Let me know! emiel@leanmanagement.nl © Lean Management Teachers 9

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