KATA

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© 2016 Jidoka®

01

TOYOTA KATAHow to Correctly Write Obstacles?

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© 2016 Jidoka®

02

Using a Well Known Challenge Game to Demonstrate Writing Obstacles

• Often, Kata Practitioners use various games and simulations to demonstrate a fast paced environment with limited resources to allow students time to practice in a relatively safe classroom environment before taking the IK/CK to actual operational situations.

• The following example is one such challenge game.• You will notice that most people start out writing short, vague phrases to

describe the obstacles keeping them from operating in the Target Condition. This is normal – everyone does this as they start practicing.

• What most students of Toyota Kata fail to see early on is that the steps of the Improvement Kata build upon each other, and the clarity of each step is dependent on the clarity of the previous step.

CurrentConditionTargetConditionObstaclesPDCAExperimentsClarity ClarityClarityClarity

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03

The TaskSet up this 200 pc domino patternas quickly as possible with 100% topple* rate.

* Domino has fallen more than 45 degrees.

25 pcs in each of

these 6 legs

50 pcs in this one leg

These Count!!!

This one doesn’t Count!!!

KATA

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© 2016 Jidoka®

04

Many times we want to write a noun or an occurrence as an obstacle:

How to Correctly Write Obstacles to the Target Condition

OBSTACLESPARKINGLOTObstacle Howwillyoumeasure that?

1 Toppletoosoon

2 ShakyTable

3 Transitionpieces

4

5

• Vague• HardtodefineagoodPDCAStep

• Can’tmeasurethis

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05

We think we are there with more description of the occurrence:

Better to Write Facts and Data as Obstacles to the Target Condition

OBSTACLESPARKINGLOTObstacle Howwillyoumeasure that?

1 We get½builtandtopple

2Thetableisshakyandifwebumpdominostopple

3Wecan’tgettransitionpiecessetcorrectly

4

5

• Moredescriptionoftheissue

• DifficulttodefineagoodPDCAStep

• Stillcan’tmeasurethis

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06

Best to Write Facts, Data, and a Negative Result – Or - A Question Needing Answers for an Obstacles

to the Target ConditionOBSTACLESPARKINGLOTObstacle Howwillyoumeasurethat?

1

Whenwestartonthe4legsof25,twoworkersinterferewiththeworkpatternandwetopplebefore completion

Topple%,andauditofstdworkpattern100%

2

Wedon’tknowawaytopreventbumpingthetableandhavetoppledtoosoontwicein eachofthelast2attempts

Wecalloutaloud“bump”andcounthowmanytimeswebumpthetable.

3

Wedon’tknowhowmanydominostosetasidetomakethetransitionpiecesattheforksandset themcorrectly

Wecountout3dominosateachtransition

Fact+Data

NegativeresultQuestionneedinganswered

Fact+Data

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07

Examples of Poorly Written Obstacles

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08

After Coaching…The Learner expanded what he/she didn’t know, but still did not write the obstacles in the proper form in order to write a clear PDCA.

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09

Obstacles Written as “To Do” Action item lists – This is counter to Kata

Writinganobstacleusingverbslike“need”,“make”,or“training”aredeadgiveawaysthattheLearnerisresortingtoingrainedhabitsofactionitemlistsresultingfromepisodicimprovementevents.

TrainingisasolutionforaPDCAstep- lackofknowledgeorskillwhichisobstacle

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10

Too Many Obstacles and Written as “Blames”– This is counter to Kata

Blamingtheoperation’scurrentconstraints, factsandrequiredpracticesorjobfunctionsareexcuses andnotobstacleidentificationwhichisthekatawayofthinking.AsaKataCoachevaluateyourLearner’sThresholdofKnowledge(TOK),coachtheLearnertoexploreinnovation,andlearntospotvictim mentality,soyoucancoachLearnersthroughobstacleidentification.

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11

Obstacles Written as Statements and Phrases – How Can We Measure These?Statementsoffactwithoutthenegativeresults,trends,ortheaffectonprocessmetricswhicharecausingagapbetweenCurrentConditionandtheTargetConditionarenotobstacles.

CoachyourLearnerstoidentifythegapbetweenCurrentConditionandTargetConditionfirst,thengivethefacts+data,followedbywhattheimpactontheprocessmetrics,thesefactsarecausing.

Thisstatementcouldbeinfinite…..

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12

Obstacles Written Correctly, with a Method of Measurement

Here we have Fact+Data+ Negative result or as a question needing answered to increase or Threshold of Knowledge (TOK)

FactsanddataalongwiththenegativeoutcomeoraquestioncausingthegapbetweenCurrentConditionandTargetCondition

Factalongwiththenegativeoutcomecausingthegap

TheDataindicateshowwecanmeasurethisobstacle

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13

Obstacles Written CorrectlyHere we have Fact+Data+ Negative result or as a question needing answered to increase or Threshold of Knowledge (TOK)

ObstacleParkingLot Howwillyoumeasurethat?WehavedeterminedthatthescraplossonthemachininglineforpartsthatareproducedfromPress105resultina0.5%scraprate.ThescraplossfrompartsproducedonPresses108and115causeascraplossof3.5%-5%.Wedonotknowthereasonsforthisdifferenceinscraplossfromthesepresssources.

Theprocessmetricofpresssetupparametersandset-uptimesonPresses108and115;theoutcomemetricofScraponthemachiningline.

Fromapreviousexploratoryexperiment,werecorded112additionalpartsovera4hourproductionrunwhenwedidnotlettheshiftruncompletely"dry"ofWork-In-Processpartsbetweenshifts.Wedonotknowtheaffectthiswillhaveacross3shiftsandifdowntimeduetominorstart-uploseswilldecreaseornot.

Totaldailyproductionanddowntimerecordedinthefirst60minutesofstartofeachshift