1. Lean
Management
Teachers
Practice Proces Analysis
Mini Kata More Often
Ideas 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 sequence
Machine 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 cycle
Process 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: outcomes
Necessary 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 Processes
Customer Demand and Line Pace Customer Demand and Line Pace
Target Output per day (1)
Number of shifts
Takt time
Planned Cycle TIme
Overview of the Process Overview of the Process
See drawing for steps; sequence and times
Number of operators
Where Work In Process
Where 1x1 flow
See run chart for output cycle fluctuation (2)
Machine Capacity Machine Capacity
Can automatic equipment support the planned cycle time?
Process Fluctuation Process Fluctuation
See run chart for operator cycle fluctuation
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
© Lean Management Teachers 4

5. We can use this Mini Kata in many phases
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
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
Manufacturing
Process: 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 Processes
Process: 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