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Kata training-2013-manufacturing-conference

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Kata training-2013-manufacturing-conference

  1. 1. Industrial Solutions - ISI KataToyota Kata Methodology for Continuous Improvement Induddddddddddddddd strial Solutions - ISI
  2. 2. Industrial Solutions - ISI Industrial Solutions - ISI •  Colin Reed, Owner •  Consulting firm, based out of Tulsa, OK •  Established in 1997 •  Full service lean manufacturing and management consulting firm •  Served hundreds of companies •  www.isiworld.net Indddduduuudddddddududddduddddddddududdduddduuuuuuuuuuuuuuuuuuuu tsts rial Solutions - ISI
  3. 3. Industrial Solutions - ISI •  Background •  Definitions, theory & purpose •  Kata program – what it looks like •  Wrap up •  Background •  Definitions, theory & purpose •  Kata program – what it looks like •  Wrap up Agenda
  4. 4. Industrial Solutions - ISI 2010 Mike Rother
  5. 5. Industrial Solutions - ISI 5 Lean Building Blocks Quick Changeover Standardized Work Batch Reduction Teams Quality at Source 5S SystemVisual Plant Layout POUS Cellular/FlowPull/Kanban TPM Culture of Continuous Improvement Value Stream Mapping
  6. 6. Industrial Solutions - ISI
  7. 7. Industrial Solutions - ISI 7 Lean Building Blocks Quick Changeover Standardized Work Batch Reduction Teams Quality at Source 5S SystemVisual Plant Layout POUS Cellular/FlowPull/Kanban TPM Culture of Continuous Improvement Value Stream Mapping
  8. 8. Industrial Solutions - ISI 8 Lean Building Blocks Quick Changeover Standardized Work Batch Reduction Teams Quality at Source 5S SystemVisual Plant Layout POUS Cellular/FlowPull/Kanban TPM Culture of Continuous Improvement Value Stream Mapping Pull/KPu Kanban C Kanb CC tinuousContCoCo tinunttinunt ar/F mprovemveve nt Flow menmem nteneentenee TPMTPMCellula Imuousuouuou ellula mproproroImusuu mpprrImusuu mpp P S ll/Kanb POUS Pu Q anKanb ty aQuali ellular/Flow uickQu Flow angk Cha ver M geov TPM urc Ce at So ce ellula St P St P ard SS tandatanda POUSPOUS Wo QQ dized ty aty a ork QualiQuali yy edu n uickuick uctio QuQu T angangk Chak Cha gg ver ms ver Team geovgeovgg atc urcurc B at Soat So ch Re cece St V St al ardard Visua tandatanda WoWodizeddized S Sy ork 5S ork eduedu n Pl nuctiouctio T Lay T ant L msms yout TeamTeamatc m atcB ystem B ch Rech Re VVV alalVisuaVisuaVisua mm PlPl LayLayant Lant L yyyoutyoutyyS SyS Sy5S5S ystemystemyyyy SSSSS uVVVVVVVVVVVVVVVaaaaaaalVVVVVVVVVV p u eare VVVVVVVaaaaal SSSStr VVVVV SSSSSSSSSS VVVVVVVVV p rereStrS MMMMMMMMMMMMMMMMMaaMMMMMMMMMM SSSSStttr MMMMMMMMMMMMMM SSSSS MMMMMMMMMMMMMMMMMM StrSStrS CConCon CuCCuCultureuultureu ofofffff tntmen
  9. 9. Industrial Solutions - ISI Background Industrial Solutions - ISI •  Traditional reporting styles & relationships •  Traditional management roles
  10. 10. Industrial Solutions - ISI
  11. 11. Industrial Solutions - ISI
  12. 12. Industrial Solutions - ISI Background Industrial Solutions - ISI •  Traditional reporting styles & relationships •  Traditional management roles •  Traditional training and development
  13. 13. Industrial Solutions - ISI
  14. 14. Industrial Solutions - ISIIndustrial Solutions - ISI •  What habits does the training break? •  How long does the effect of the class last? •  What culture change has come of it? •  What has TRULY been learned?
  15. 15. Industrial Solutions - ISI Background Industrial Solutions - ISI •  Traditional reporting styles & relationships •  Traditional management roles •  Traditional training and development •  Traditional project management •  Projects come and go
  16. 16. Industrial Solutions - ISI
  17. 17. Industrial Solutions - ISI Background Industrial Solutions - ISI •  Traditional reporting styles & relationships •  Traditional management roles •  Traditional training and development •  Traditional project management •  Projects come and go •  Benchmarking others
  18. 18. Industrial Solutions - ISI Results of Benchmarking
  19. 19. Industrial Solutions - ISI
  20. 20. Industrial Solutions - ISI Purpose for Kata •  Develops people •  Reveals people’s true potential •  Coach/Learner role is for guidance •  Forces us to truly understand the current condition •  Gets all involved out of their comfort zone, where we are truly learning Industrial Solutions - ISI
  21. 21. Industrial Solutions - ISI Kata Movie
  22. 22. Industrial Solutions - ISI Kata Tools = Growth
  23. 23. Industrial Solutions - ISI Kata vs. Kaizen Event •  A Kaizen Event is one in which a team of people work towards a specific objective over a compressed period of time Industrial Solutions - ISI
  24. 24. Industrial Solutions - ISI
  25. 25. Industrial Solutions - ISI Kata vs. Kaizen Event •  A Kaizen Event is one in which a team of people work towards a specific objective over a compressed period of time •  Kata is daily, built into fabric of management’s daily standard work Industrial Solutions - ISI
  26. 26. Industrial Solutions - ISI 26 Why progress is not consistent Time KE 1 What Standard should be What actually becomes the Standard when people do not sustain the changes? Work Standard What Standard should beKE 2 KE 3
  27. 27. Industrial Solutions - ISI Kata vs. Kaizen Event Industrial Solutions - ISI
  28. 28. Industrial Solutions - ISI Kata vs. Kaizen Event Industrial Solutions - ISI Vision Time TC TC TC Time What Standard should be Work Standard What Standard should beKE 2 KE 3 KE 1
  29. 29. Industrial Solutions - ISI •  Background •  Definitions, theory & purpose •  Kata program – what it looks like •  Wrap up •  Background •  Definitions, theory & purpose •  Kata program – what it looks like •  Wrap up Agenda
  30. 30. Industrial Solutions - ISI Definitions Industrial Solutions - ISI •  Vision •  Challenge •  Target Condition •  PDCA – Plan/Do/Check/Act •  Learner, Coach, 2nd Coach
  31. 31. Industrial Solutions - ISI Vision Industrial Solutions - ISI •  Where is the company going? •  What does it want to be, to pursue? •  Long term: beyond 2, 5, 10, 20, 50+ years?
  32. 32. Industrial Solutions - ISI Vision
  33. 33. Industrial Solutions - ISI Vision Industrial Solutions - ISI Toyota’s Vision* •  Zero Defects •  100% value added •  One-piece flow, in sequence, on demand •  Security for people *p. 44 Toyota Kata, by Mike Rother
  34. 34. Industrial Solutions - ISI Vision Industrial Solutions - ISI
  35. 35. Industrial Solutions - ISI Vision Industrial Solutions - ISI
  36. 36. Industrial Solutions - ISI Vision Industrial Solutions - ISI
  37. 37. Industrial Solutions - ISI Definitions Industrial Solutions - ISI •  Vision •  Challenge •  Target Condition
  38. 38. Industrial Solutions - ISI Challenge Industrial Solutions - ISI •  A near term, obtainable goal that is a step towards the future state or vision Vision Challenge Challenge TC TC TC TC
  39. 39. Industrial Solutions - ISI Definitions Industrial Solutions - ISI •  Vision •  Challenge •  Target Condition
  40. 40. Industrial Solutions - ISI Target Condition Industrial Solutions - ISI •  A near term, obtainable goal that is a step towards the current Challenge
  41. 41. Industrial Solutions - ISI Target Condition
  42. 42. Industrial Solutions - ISI
  43. 43. Industrial Solutions - ISI Target Condition Industrial Solutions - ISI Examples: • Balance the cycle times in a work cell • Establish flow, FIFO and SWIP between work centers for XYZ part family • Eliminate changeovers where we have 3 fixtures currently
  44. 44. Industrial Solutions - ISI Definitions Industrial Solutions - ISI •  Vision •  Challenge •  Target Condition •  PDCA – Plan/Do/Check/Act
  45. 45. Industrial Solutions - ISI PDCA Industrial Solutions - ISI
  46. 46. Industrial Solutions - ISI   Plan - “Hypothesis”   Do - “Experiment”   Check - “Compare to hypothesis”   Act/Adjust - “Reformulate the hypothesis” Plan-Do-Check-Act/Adjust is a rephrasing of the Scientific Method: • 46 The PDCA Cycle
  47. 47. Industrial Solutions - ISI Definitions Industrial Solutions - ISI •  Vision •  Challenge •  Target Condition •  PDCA – Plan/Do/Check/Act •  3 Main Roles in Kata: •  Learner •  Coach •  2nd Coach
  48. 48. Industrial Solutions - ISI 3 Main Roles in Kata Learner, Coach, 2nd Coach •  Develops mentoring structure with a one-on-one relationship •  Usually based on reporting chain •  Sequence starts with front line process, continues up to top levels Industrial Solutions - ISI
  49. 49. Industrial Solutions - ISI 3 Main Roles in Kata Learner/Coach sequence starts with front line process, continues up to top levels Industrial Solutions - ISI Plant Manager VSM Manager Manager Supervisor Front Line LearnerLearnerLearnerLearner Coach Coach Coach Coach
  50. 50. Industrial Solutions - ISI 3 Main Roles in Kata Learner: owner of the process to target •  Conducts the PDCA cycles to experiment on a process to work towards a Target Condition •  Develops new PCDA after examining the cause and effect of the previous experiment Industrial Solutions - ISI
  51. 51. Industrial Solutions - ISI 3 Main Roles in Kata Learner: •  Should be encouraged to try ideas, pushed/challenged to innovate •  It’s okay to fail & have an idea not work – actually expected to occasionally, otherwise not pushing the envelope hard enough Industrial Solutions - ISI
  52. 52. Industrial Solutions - ISI 3 Main Roles in Kata Coach: mentor that directs & guides the Learner Industrial Solutions - ISI
  53. 53. Industrial Solutions - ISI 3 Main Roles in Kata Coach: mentor that directs & guides the Learner •  Questions the Leaner’s understanding of the current and target conditions, ensures the next step takes those into account Industrial Solutions - ISI
  54. 54. Industrial Solutions - ISI 3 Main Roles in Kata Coach: mentor that directs & guides the Learner Industrial Solutions - ISI
  55. 55. Industrial Solutions - ISI 3 Main Roles in Kata Coach: •  Reviews the cause and effect of the Learner’s approach and the gains made towards the Target Condition Industrial Solutions - ISI
  56. 56. Industrial Solutions - ISI 3 Main Roles in Kata Coach: •  Is practicing Coaching, learning how to do it •  Must change how they see their relationship with the Learner Industrial Solutions - ISI
  57. 57. Industrial Solutions - ISI 3 Main Roles in Kata Coach: •  Needs guidance as well: the 2nd Coach Industrial Solutions - ISI
  58. 58. Industrial Solutions - ISI 3 Main Roles in Kata 2nd Coach: observes, directs & guides the Coach to be more effective •  Reviews the cause and effect of the Coach’s approach and the Learner’s continued development •  Provides instruction to Coach •  Role may diminish over time, but isn’t eliminated Industrial Solutions - ISI
  59. 59. Industrial Solutions - ISI 3 Main Roles in Kata Key points: •  The role of Learner is the one performing the hands-on experiment, seeing and interpreting the results •  The coach ask questions, doesn’t solve the problem, lets the Learner learn Industrial Solutions - ISI
  60. 60. Industrial Solutions - ISI Management’s Role •  Expectations •  Must be ready to Walk the Walk •  Setting Vision •  Give goal – no solutions or pre-judgments of how
  61. 61. Industrial Solutions - ISI •  Background •  Definitions, theory & purpose, roles •  Kata program – what it looks like •  Wrap up •  Background •  Definitions, theory & purpose, roles •  Kata program – what it looks like •  Wrap up Agenda
  62. 62. Industrial Solutions - ISI Program Development •  Set the Vision •  Develop the Advance Group •  Establish the program structure •  Learn the Kata Coaching methods •  Set Target Conditions Industrial Solutions - ISI
  63. 63. Industrial Solutions - ISI Program Development Sequence Set the Vision •  Long term goals – to shoot for, “True North” •  Ex.: Toyota: to achieve 100% Value Added •  Can be an unattainable goal, can be hard numbers •  Gives a horizon to head towards Industrial Solutions - ISI
  64. 64. Industrial Solutions - ISI Program Sequence •  Set the Vision •  Develop the Advance Group Industrial Solutions - ISI
  65. 65. Industrial Solutions - ISI Program Sequence Develop the Advance Group •  Update the Org. Chart •  Top and middle management must participate •  Will depend on the companies ability to properly coach all Learners Industrial Solutions - ISI
  66. 66. Industrial Solutions - ISI Program Sequence •  Set the Vision •  Develop the Advance Group •  Establish the program structure •  Learn the Kata Coaching methods •  Set Target Conditions Industrial Solutions - ISI
  67. 67. Industrial Solutions - ISI Program Sequence •  Set the Vision •  Develop the Advance Group •  Establish the program structure •  Learn the Kata Coaching methods •  Learn by doing •  Use the program development as first kata Industrial Solutions - ISI
  68. 68. Industrial Solutions - ISI Program Sequence •  Set the Vision •  Develop the Advance Group •  Establish the program structure •  Learn the Kata Coaching methods •  Set initial Target Conditions Industrial Solutions - ISI
  69. 69. Industrial Solutions - ISI Program Sequence Target Condition: •  Value Stream / Strategic Plan a good place to first start •  Start with something attainable in 2-3 weeks, progress to greater challenges from there Industrial Solutions - ISI
  70. 70. Industrial Solutions - ISI Daily Kata •  Is performed daily •  Is designed to be a slice of the Learner’s day •  Coaching sessions are sacred & take priority Industrial Solutions - ISI
  71. 71. Industrial Solutions - ISI Learner Story Board Industrial Solutions - ISI Process Challenge Target Condition Current Condition PDCA Data Obstacles Metrics Metrics
  72. 72. Industrial Solutions - ISI 2 3 Operators Cycle Time Takt Time Std WIP 3 13 min 15 min 10 sub-assy max 1 8, 9, 10 3, 4, 5, 6 7 Cell Standard Work Breakdown Step Operator Task WIP (max) 1 3 Get paperwork, alert QC to next order - 2 1 Move boxes into place - 3 1 Upper Assembly 10 4 1 Lower Assembly 10 5 1 Cage Assembly 10 6 1 Bottom Brace Assembly 10 7 3 Chain Assembly 10 8 2, 3 Lower Assy 2 9 2, 3 Upper Assy 2 10 2, 3 Final Assy 2 11 3 Band parts to pallet - 12 3 Wrap skid (Op 2 Assist), take to Shipping - 13 1 Remove empty boxes - Inserts PalletPallet 13 2 8, 9, 10 1, 11, 12
  73. 73. Industrial Solutions - ISI 2 3 Operators Cycle Time Takt Time Std WIP 3 13 min 15 min 10 sub-assy max 1 8, 9, 10 3, 4, 5, 6 7 Cell Standard Work Breakdown Step Operator Task WIP (max) 1 1 Get paperwork, alert QC to next order - 2 1 Move boxes into place - 3 1 Upper Assembly 10 4 1 Lower Assembly 10 5 1 Cage Assembly 10 6 1 Bottom Brace Assembly 10 7 3 Chain Assembly 10 8 2, 3 Lower Assy 2 9 2, 3 Upper Assy 2 10 2, 3 Final Assy 2 11 3 Band parts to pallet - 12 3 Wrap skid (Op 2 Assist), take to Shipping - 13 1 Remove empty boxes - Inserts PalletPallet 1, 13 2 8, 9, 10 11, 12
  74. 74. Industrial Solutions - ISI Action Prediction Results LessonsA ti LR ltP di ti PDCA Cycle Record 1st 2nd
  75. 75. Industrial Solutions - ISI Action Prediction Results LessonsA ti LR ltP di ti PDCA Cycle Record 1st Step Do I clearly understand what action I should take to improve, am I addressing an obstacle? Am I truly experimenting? How do I think this will help us improve?
  76. 76. Industrial Solutions - ISI Action Prediction Results LessonsA ti LR ltP di ti PDCA Cycle Record Have Op. 1 perform Step 1 instead of Op. 3. Will give Op. 3 additional 30 seconds to band pallet.
  77. 77. Industrial Solutions - ISI Coaching Session Industrial Solutions - ISI COACHINGKATA p. 247, Toyota Kata, by Mike Rother
  78. 78. Industrial Solutions - ISI Coaching Session Industrial Solutions - ISI p. 247, Toyota Kata, by Mike Rother Info part of last Coaching Session. Info hasn’t been covered yet.
  79. 79. Industrial Solutions - ISI Coaching Session Industrial Solutions - ISI COACHINGKATA p. 247, Toyota Kata, by Mike Rother
  80. 80. Industrial Solutions - ISI Obstacles Industrial Solutions - ISI
  81. 81. Industrial Solutions - ISI Learner Story Board Industrial Solutions - ISI Process Challenge Target Condition Current Condition PDCA Data Obstacles Currently known
  82. 82. Industrial Solutions - ISI Coaching Session Industrial Solutions - ISI COACHINGKATA p. 247, Toyota Kata, by Mike Rother
  83. 83. Industrial Solutions - ISI Action Prediction Results LessonsA ti LR ltP di ti PDCA Cycle Record 2nd Step Reflect on the data collected. Did we find or solve obstacles? Confirms or refutes our existing knowledge.
  84. 84. Industrial Solutions - ISI Action Prediction Results LessonsA ti LR ltP di ti PDCA Cycle Record Have Op. 1 perform Step 1 instead of Op. 3. Will give Op. 3 additional 30 seconds to band pallet. Op. 1 was able to do it in the cycle time, but still NVA to walk to QC every time. -  Need better alert method -  Train Operators on self inspect of hardness tests, 1/3 of orders
  85. 85. Industrial Solutions - ISI •  Background •  Definitions, theory & purpose •  Kata program – what it looks like •  Wrap up •  Background •  Definitions, theory & purpose •  Kata program – what it looks like •  Wrap up Agenda
  86. 86. Industrial Solutions - ISI Take Away’s •  Not just a new project – A total change of management and their style, of the entire organization •  Not just for shop, should be applied in all areas
  87. 87. Industrial Solutions - ISI Take Away’s •  Make part of DAILY activities •  Does not get low priority •  Must be a Learner before being a Coach
  88. 88. Industrial Solutions - ISI Success Factors for Kata •  Physical •  Training •  Mental Industrial Solutions - ISI
  89. 89. Industrial Solutions - ISI Physical: •  Have lean tools have been used to improve on a team basis? •  Do we have work standards established? •  Have we started to flow material? Industrial Solutions - ISI Success Factors for Kata
  90. 90. Industrial Solutions - ISI Training: •  Does the Learner understand waste elimination, problem solving & the Lean Tools to overcome issues? •  Does the management team understand improvement well enough to effectively create Challenges & Target Conditions? Industrial Solutions - ISI Success Factors for Kata
  91. 91. Industrial Solutions - ISI Training: •  Is standard work being followed •  5S, Work Instructions, SWIP, Set-Up Checklists, TWI, TPM, etc. Industrial Solutions - ISI Success Factors for Kata
  92. 92. Industrial Solutions - ISI Mental: •  Do employees feel empowered? •  Has a culture change started to take place? •  Are there consequences for in- action? Industrial Solutions - ISI Success Factors for Kata
  93. 93. Industrial Solutions - ISI Mental: •  Does the Management have self- discipline themselves? •  Is the management team ready to live the new lifestyle? •  Is Management ready to hold accountable those that don’t participate? Industrial Solutions - ISI Success Factors for Kata
  94. 94. Industrial Solutions - ISIions - ISI Mental: is the management… •  Willing to re-learn how to manage? •  Willing to feel out of your element? •  Willing to let someone fail to learn? •  Willing to not give the answer? •  Willing to (seemingly) give up some control? Industrial Solutions - ISI Success Factors for Kata
  95. 95. Industrial Solutions - ISI Thank you! WWW.ISIWORLD.NET

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