lean management kata training

Lean Management + Kata TrainingLearning Lean practicing with Lean Kata Trainer

January 2017

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www.focuslean.com

• Lean Management current situation• What Kata is?• The Improvement Kata model.• Student training goals.• Methodology = Gamification = Lean Kata Trainer.

Lean Management + KataContents

• Methodology = Gamification = Lean Kata Trainer.• LeanKata Trainer videogame structure.• Knowledge and change of habits to gain.• To whom it is addressed.• Videogame LKT designer and trainer.

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Lean Management + KataLean Management current situation

20th centuryPeriodic

21th centuryDaily

LEAN MANAGEMENT

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SCIENTIFIC THINKING

Lean groupEliminate waste

Toyota based must do

ManagersStrategic objectives

We do what we must do

Lean Management + KataWe have learned Lean as a set of recipes and tools that we necessarily want to apply in our processes...

AND THIS IS NOT ALWAYS POSSIBLEWe need something MORE, we need to learn to use:

4THE SCIENTIFIC THINKINGWe need something MORE, we need to learn to use:

To ensure that everyone in an organization learn how to improve any process.

Lean Management + Kata

“Let́ s try it and see"

SCIENTIFIC THINKINGIt is a routine is a routine of intentional coordination between what we think will happen (theory), what actually happens (evidence), and adjusting based on what we learn from the difference.

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What we expect to happenWhat actually happenedLearning


Visible Lean tools and techniques to improve quality, cost and delivery

Where we are focused in Lean now

6LessVisible• A systematic, scientific way of thinking and acting• Managers as the teachers of that way

We DON´T practice the basic skills of scientific thinking

Lean Management + Kata4 INGREDIENTS FOR ACQUIRING NEW SKILLS

The following ingredients help us rewire our brain (new neural circuits) to acquire new skills & mindset.

k COACHINGSTARTERKATA lStructured routines

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This is how you do it j FREQUENTPRACTICE MASTERY mCorrective feedbackto ensure the Learner practices the rightpatterns

Growing self efficacy"I'm getting better at this"

Structured routinesfor beginnersto practicefundamentals

A little every dayBy Mike Rother

Lean Management + Kata• They're practice routines.• With Kata the patterns become habits and leaves you with new abilities. • Kata are for learning fundamentals that you can build on.• Kata are a way of transferring skills and developing shared abilities and mindset in a team or organization.

“Let’s begin by practicing it this way for a while”

What Kata is?

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Combining a scientific pattern with structured practiceroutines (Kata) develops effective problem solvers.By Mike Rother

Science + Kata = Problem Solving Skill

Lean Management + KataKATA ARE LIKE ROCKET ENGINES

KATA9

They help you get started

Lean Management + KataWe found a common, scientific pattern of thinking and behavior in Toyota managers' approach -- their 'Way of Improving' -- and depicted it with a four-step model we named the “Improvement Kata.”

The Improvement Kata model

Establish

Get the Direction orChallenge3

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By Mike Rother

Conduct Experimentsto get thereGrasp the CurrentCondition

Establish your NextTargetCondition 12 4

The Improvement Kata model comes from research into how Toyota manages people, which is summarized in the book “Toyota Kata”

Lean Management + KataTHE SCIENTIFIC LEARNING CYCLEThe scientific process of acquiring knowledge

PREDICTIONTestable

EVALUATEAdjust based on what you learn PLANACT

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This cycle gives you a practical way to reach your Target Condition, by providing a systematic way of working through the grey zone between here and there.By Mike Rother

ACTIONConduct theexperiment

what you learn

EVIDENCECollect facts and data

PLANDO

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4CHECK(Study)

ACT

Lean Management + KataDO YOUR TESTS IN THE"EXPERIMENTING ZONE"

A measureableTarget Conditionwith achieve-by dateCurrentCondition

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By Mike Rother

Using an effective means or pattern (Kata) for experimenting

Itʼs within these boundary conditions that we design and conduct frequent, rapid, cheap, non-harmful, successive experiments toward the Target Condition. Experiments are done as cheaply, quickly and safely as possible.

Lean Management + KataBUT THERE IS A PROBLEMNo matter how good it is, just explaining a modeldoesn't generate new ways of thinking and acting.Hoping to create different behavior by explainingor trying to convince generally doesn't work.

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Kata are also practice routines that help you adopt new ways of acting and thinking.

THE ROLE OF PRACTICE ROUTINES

14This is where brainscience comes in

Student training goals • Learn and assimilate the fundamental concepts upon which the Lean Management is based. • Generate the ability to apply these concepts to carry out improvement projects implementing Lean in their companies.


• Learn the techniques of the Improvement Kata for process improvement.• Start in the principles of the Coaching Kata.• Create habits and structured routines that allow the students started in the Kata and progress towards a Target Condition.

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Lean Management + KataAND THE TECHNOLOGY HELP US

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Lean Management + KataTo carry out this training of the improvement Kata and coaching Kata for processes, has been designed a gamification digital product :

Lean Kata Trainer

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Methodology = Gamification = Lean Kata Trainer. (LKT)• The LKT is a video game for the Lean Management + Kata training that works at the same time about 15 tablets, synchronously, in a training classroom.• With the LKT each student performs its task on a tablet and performs the operations of the process that corresponds to his/her job.


• The LKT video game simulates the behavior of a process of a company in different scenarios and situations.• With the LKT the students are trained in Lean Management + Kata playing and progressing through the 5 levels in which is structured the game.

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• Learn with Lean Management to manage the processes of a company in a different way.• Know and apply the improvement Kata tools in the processes. • Create in the students the routines of Kata as a form of transferring skills

During this training, the student will acquire the following knowledge and skills:


• Create in the students the routines of Kata as a form of transferring skills and develop shared capabilities and attitudes in a team or in an organization. • Knowing the Kata coaching for a change of culture. • Experience continuous learning in process improvement.• Reduce the operational costs of the processes. • Increase the true contribution of value to customers.

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5-26 October 2016: courses in the Carlos III Industrial Engineering University (Madrid)Lean Management + Kata

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21https://www.youtube.com/watch?v=YKJ9I8eiJp8


k LEARN COACHINGCREATE KATA l

THE Lean Kata Trainer CYCLE

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LEARN ANDPRACTICE BECOME AMASTER mThis is how you do it

j

Processes

Lean Kata Trainer (LKT) videogame estructure Lean Management + Kata

LUCOS Customer RESULTS

ProductsThe context

Processes23

The gameN1 N2 N3 N4 N5

Lean Management KATA

Game LevelsThe team

The ChallengeThe Challenge

CurrentManagement System

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Lean Management + KataThe Lucos team

General Director The processThe processFinancial Director Team Leader 24General Director The processThe processFinancial Director Team Leader

The Customer

Lean Management + KataThe Kata method in the LKT The Challenge

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By Mike Rother

LKT videogame levelsLean Management + Kata

impro

veme

nt KA

TA

Pull System Poka Yoke

N4 Kanban KanbanBatch size = 1 Demand variability SupermarketModelPull

N5 MTO* *Make to OrderNew products NewProduct

Level Scenario Screen Lean Tools Target Condition

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N1impro

veme

nt KA

TA

Job cells Work in cellsBatches planning Zero breakdownsSMED ProcessStabilization

N2 Flow Work in flowBalanced work StandarizationJidoka Work inflow

N3 Pull Pull SystemWIP limit Poka Yoke PullProcessAndon

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Lean Management + KataThe rules of the LKT

• 5 levels of progress. • Time of each round = 12 minutes. • Team of 15 people. 27• Team of 15 people. • A Customer. • Inmediate results after each round. • Change of variables based on the PDCA.

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Lean Management + KataThe achievement in the LKT

Lean Management New Products

Supermarket

Pull Costs

New Markets

New Customers

Q 28Flow

ProcessStabilizationCurrent Situation

Quality

To whom it is addressedThis training has been designed for professionals from the different levels of the company and in particular:• potential leaders that they intend to change the culture and carry out a real plan of Lean implementation (managers, technicians, supervisors). • personas que vayan a trabajar en un entorno Lean formando parte de equipos de


• personas que vayan a trabajar en un entorno Lean formando parte de equipos de mejora en una empresa (Empleados, Operarios, Administrativos).• people who go to work in an environment Lean as members of improvement teams in a company (employees, machinists, administrative).• University students, teachers, consultants, business advisors and entrepreneurs.

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• Carlos Martín Maroto is an Industrial Engineer. • PDD from IESE. • Manufacturing Director at Philips TV Barcelona. • Supply Chain Director at Lucent Technologies Spain. • Director of photovoltaic manufacturing at Abengoa Solar.• Associate Professor in the Department of Operations of the Universidad Carlos

Videogame LKT designer and trainerLean Management + Kata

• Associate Professor in the Department of Operations of the Universidad Carlos III (Madrid) • Lean Management trainer in different companies.As a professional, Carlos Martín Maroto has participated in numerous projects of Lean Management implementation throughout his career.

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www.focuslean.com@focuslean Carlos Martín Marotofocuslean

31Contact: Carlos Martín [email protected] +34 601 050 145

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lean management kata training

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