lecture 3a

KATA

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© 2016 Jidoka®

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TOYOTA KATAEstablishing theTarget Condition

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The Improvement Kata

ESTABLISH THE TARGET CONDITIONPractice

thisRoutine

For reference see:

Chapter5

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Wearehere Wewanttobehere

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A TARGET CONDITION ENABLES TEAMWORK

With a Target Condition

Let’stryandoperateintheTargetconditionandseewhat

areourrealobstacles?

Howmanyobstaclecanwesee?

“Let’stryyouridea”…“But,Ilikeyourideabetter

WhatdoweneedtotrytooperateintheTargetCondition

?PDCA/PDSAispossible!

No Target Condition

Who’sopinionisright?

Howdoweprioritizeourobstacles?

Whatistherealproblem?

“Ilikemyidea,notyours”…”AndIlikemyidea”

PDCA/PDSAisimpossible

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Process Metrics vs Outcome MetricsManypeoplehavedifficultyunderstandingtherelationshipanddifferencesbetweenaProcessMetricandanOutcomeMetrics.Theconcepttheyfailtounderstandistwofold:

1. ProcessMetricsaremeasurementsinrealtime.Itishoweverpossibletoconsiderameasurementeitheratacertainpointintimepastthebeginningoftheprocessormaybeattheendoftheday.ProcessMetricsaremetricsthatyoucangather“inthemoment”• Examplearesuchaconstructionofarunchartinthepreviousslidesonlowest

repeatableprocesscycletimeorthevariationfromcycletocycle.• Anotherexampleisrework.Wecanmeasurethefirstpassyield(FPYforthedayat

anypointintheshiftandknowatwhatratewearehavingtorework

2. ProcessMetricsaffectormanytimesdeterminethevalueswegetasOutcomeMetrics.ManytimeswerefertotheProcessMetricasthe“lever”thatcontrolstheOutcomeMetric.• Example:AnOutcomeMetricforapotofboilingwaterisdeterminedbytheProcess

Metricofthestoveburnerelement.

ProcessMetric=KnobSetat7

OutcomeMetric=TemperatureofWateris100oC

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RelationalAnalogiesofProcessCharacteristics,ProcessMetrics,andOutcomeMetrics...

• Characteristic – afeature orqualitytypically belonging toaperson, place,orthing andserving toidentify it

• Attribute – toconsider asaquality orcharacteristic oftheperson,thing,group, etc.

Describes howweplaythegame

PROC

ESSC

HARA

CTER

ISTIC

OR

ATT

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• ProcessMetrics - Standards ofmeasurement bywhichefficiency,performance, progress, orquality ofaplan, process, orproduct canbeassessed

ProcessMetricsarekeyindicators fromwithin the processitself thatsuggestwhatcanbeexpected with theOutcomeMetrics… ProcessMetrics haveanindirect(ordirect) impactonOutcomeMetrics.

Howweareperforming within the game

PROC

ESSM

ETRI

CS

• OutcomeMetrics - Determination andevaluation oftheresults ofanactivity,plan, process, orprogram andtheircomparison withtheintended orprojected results

OutcomeMetricsarefinalscores thatprovide clearandconcise understandingastohowthe processisperformingagainstthestandard ortargetcondition.

Thescoreofthegame

OUTC

OMEM

ETRI

CS

Definitions&Descriptions

Weareagood freethrow shooting team–91%(freethrow shooting percentage).Wesetplaystodrive intothelaneanddrawcontact (foul) fromtheopposing teamtogetahighnumber offreethrow attemptsinthegame,putting morepoints onheboard, andabetter chance atwinning thegame.


PROC

ESSC

HARA

CTER

ISTIC

OR

ATT

RIBU

TE

• Foulsdrawn• Shooting Fouls• Floor Fouls

• Number ofFreeThrow attempts• FreeThrowshooting percentage

• FreeThrowshootingpercentage onfront endof1&1

Howweareperforming within the gamePROC

ESSM

ETRI

CS

• FinalScoreofthegame• Win/Lossrecord

ThescoreofthegameOU

TCOM

EMET

RICS

ASportsAnalogy

Weexecute toschedule onallrecommended preventative andpredictivemaintenance activities onourpress.ForPMworkthat can’tbedonewith thepressrunning or insetup, weallot 4hours(planned down time)onMondaysforPMactivity.


PROC

ESSC

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ISTIC

OR

ATT

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• OverduePMWorkOrders• Unplanned Maintenance hours(reactive – breakdowns)

Howweareperforming within the gamePROC

ESSM

ETRI

CS

• PressUpTimePercentage

Thescoreofthegame

OUTC

OMEM

ETRI

CS

ACMEGear,CO.Example

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Target vs Target ConditionProcess Characteristics: Indoor or Outdoor?

The Target = BullseyeProductivity, Scrap, Infection rate

The Target Condition has Process Characteristics like indoor archery

or outdoor archery. For Mfg Number of shifts or operators; Medical frequency of dressing

changes

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Target vs Target ConditionLarge competition or Small local competition

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Process Characteristic = WIND

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Process Characteristic =5 C Cold vs Hot 45 C

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Process Characteristic =Sunny vs Dusk vs Rain?

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Process Characteristic =Traditional vs Nontraditional

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Process Characteristic = Equipment

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WHAT INFORMATION IS IN A TARGET CONDITION?

How the game is

played

The score

• A target condition should include a target date + these four categories of information.• No verbs in a target condition! That's for how to get there.

Next

Next

Next

Often,thesearedecidedfrom

the“BottomUp”First

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ThefollowingslidesareexampleformsofprovenwaystoestablishthenextTargetCondition

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TARGET CONDITIONS RECORD (ONEPAGE PERTARGETCONDITIONPERIOD)

KATA:CHALLENGE (include details, not justthechallenge name):

STARTDATEOFNEWTARGETCONDITIONPERIOD:_____________

END DATEOFNEWTARGETCONDITIONPERIOD:______________

COACHINGCYCLE(BETWEEN COACH &2ND COACH) DATE:_____ TIME:_____

COACH:_________2ND COACH:_________LEARNER:_________

TARGETCONDITIONTHEME FUTURE STATEDETAILS(WHATDOYOUEXPECT?)

Whathappened? (observeclosely)

Whatdidyoulearn?(what youexpected?/whathappened?)

COAC

HIN

GCY

CLE

/EX

PERI

EMEN

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FACTS&DATA?

WASANOBSTACLEELIMINATED?

WHATIMPROVEMENTSWEREMADE…WHAT

STANDARDSWEREPUTINPLACE?

WHATARETHEMETRICANDCAHRACTERISTICVALUESCOMPAREDTO

WHATYOUEXPECTED…LISTTHEMOUT…WHATISTHE

%OFATTAINMENT?

ABOUTTHEPROCESS?

ABOUTTHEOBSTACLES?

ABOUTSCIENTIFICPROBLEMSOLVING?

ABOUTSETTINGTARGETCONDITIONSFORTHIS

CHALLENGE?

WHATSPECIFICALLYWILLCHANGEFROMTHECURRENT

CONDITION?

WHATARETHEMETRICSANDCHARACTERISTICSFORTHEKATA(LISTTHEMOUT)…WHATARETHECURRENTVALUESTODAY,ANDWHATWILLTHEVALUESBEATTHE

ENDOFTHETARGETCONDITION?

WHATWILLBETHEFOCUS FORTHISTARGET

CONDITIONPERIOD?

WHATOBSTACLEAREYOUFOCUSEDON?

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STARTDATEOFNEWTARGETCONDITIONPERIOD: END DATEOFNEWTARGETCONDITIONPERIOD:

COACHINGCYCLE(BETWEEN COACH &2ND COACH) DATE: TIME: COACH: 2ND COACH:LEARNER:

TARGETCONDITIONTHEME

FUTURE STATEDETAILS(WHATDOYOUEXPECT?)


Whatdidyoulearn?(what youexpected?/what

happened?)

COAC

HIN

GCY

CLE

/EX

PERI

EMEN

TS









happened?)

COAC

HIN

GCY

CLE

/EX

PERI

EMEN

TS

A B

C

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happened?)

FirstdefineyourTCthemeandobstacles

NextwhatwilltheTCProcess CharacteristicsandMetricslooklike

COAC

HIN

GCY

CLE

/EX

PERI

EMEN

TS OncetheTChasended,

evaluatewhathappened.Whatstandardsareinplace?

Whatdid youlearnoverthepast2-4weeks?Whatwould youhavedone differently?









happened?)

DefineyournextTCthemeandobstacles

What willTC#2looklike?WhatwilltheProcessCharacteristicsandMetrics? CO

ACHI

NG

CYCL

E/

EXPE

RIEM

ENTS

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Date: 3 July Regional QualificationsProcess Characteristics• 2 Outdoor competitions, 2 rounds each

• Morning event: Outdoor• Afternoon event: Indoor

• Audience of 250-350 people• Forecast: Mild and Sunny day, Temp = 27o

C, wind NW at 25 km/hr.• Equipment is:

• Morning event: Recurve bow competition, 60s max/shot, stabilizers allowed, target tips with150 grain max weight

• Afternoon event: Long bow competition, 60s max/shot, no stabilizers, target tips with100 grain max weight

• Distances 18m, 28m, 45m, and 68mProcess Metrics• 10 point/rd. scoring, 10 Targets/rd.

Outcome Metrics• Highest round scores win 3 medals, Gold,

Silver, or Bronze

Achieve by: 3 JulyProcess Characteristics• Takt Time = 55 s• Planned Cycle Time = 47 s• No. of Operators = 3

• Shifts = 2 at 8 hours each• Two 15 min breaks, One 40 min lunch and

all are paid time• Cellular flow with 3 work cells, 7 machines

total• Flow is continuous 1x1• Standard WIP at Sawing, Drilling, and

Welding cellsProcess Metrics• Production rate = 65 units/hour• Exit cycle variation (Hi/Lo) = +/- 20%Outcome Metrics• 575 units/shift, 192 Units/labor hour• Scrap factor = 1.3%

Target Conditionfor Archery

Target Condition forManufacturing

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Target Condition Side of the Storyboard –Healthcare, Emergency Dept.

Achieveby:3July

ProcessCharacteristics• Capacityof215patientsin24hours• 45beds,MedicalscreeningandTrauma• No.ofNurses=12on0700-1500,18on1500-2300,14on2300-0700• Two15minbreaks,One30minlunch

ProcessMetrics• LabsTurnaroundtime(TAT):

• Bloodpanels=30min;Urinalysis=25min;Radiology =20min

OutcomeMetrics• PatientLengthofStay(LOS)tod/c<220min• PatientLengthofStay(LOS)toadmit <260min

EMSarriveswithpatient

TraumaorMedicalScreening?

MedicalScreeningExam-Physician

LabsorderbyPhysician

PhysicianDiagnosis &TreatmentbyNurse

Dischargedoradmitted

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TargetConditionAchieveby:06.10.2016

CurrentCondition

ProcessMetrics ProcessMetrics

OutcomeMetrics OutcomeMetrics

F/A-Pack

Mill8

Mill7

Mill6

Mill5

Mill4

Mill3

Mill2

Mill1

CNC2

CNC1

Shaper6

Shaper5

Shaper4

Shaper3

Shaper2

Shaper1

Hob18

Hob17

Hob16

Hob15

Hob14

Hob13

Hob12

Hob11

Hob10

Hob9

Hob8

Hob7

Hob6

Hob5

Hob4

Hob3

Hob2

Hob1

Hob0

Hob1

50

48

46

44

42

40

38

36

34

32

30

28

26

24

22

20

18

16

14

12

10

8

6

4

2

0

OTHERPROCESSMETRICS:

MillReliabilityis80%

OvertimeisduetomachinereliabilityatTurningMills1,7,&8

NOTESANDOBSERVATIONS

PROCESSCHARACTERISTICS:

Wehaveexcesscapacityandhighvariationinmachinecycle

withourHobMachines.Hob18cycletimeexceedsTaktTime

Wehaveexcesscapacityandhighvariationinmachinecycle

withourTurningMillMachines.

PPLH=27.5

Scrap=6.7%

OverTime=8%

FirstPassYield=93%

ExitCycleVar(Pack)=10s+/-12%

Hob18LowestRepeatable HiVar=+195%

LoVar=-24%=14seconds

TaktTime=12.3seconds

PlannedCycleTime=10.5Seconds

NumberofShifts=3

NumberofOperators=10

CURRENTCONDITIONSUMMARYSHEET

OutcomeMetrics(SeeCharts)

ProcessStability:

FirstPassYield> 95%MillReliability> 85%

PPLH> 37.5Scrap< 5%Overtime<10%

FocusProcess: Challenge: ItwouldbeColossal,ifby1.1.2017,theACMEmachiningcelloccupied50%lessfloorspace,operating2shiftswith50%ofthemachinery,sowecanachieve:50PPLH,< 3.5%Scrap,withNoOvertimeACMEMachiningCell

Obstacle

1

2

3

4

5

Workload on operators

Scrap

OBSTACLESPARKINGLOTHowwillyoumeasurethat?

Less number of Hobs

Less number of Turning Mills

lecture 3a

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