TOYOTA KATA

develop a sustaining culture of Continuous Improvement in your organization

Some Quick History…

Continuous Improvement efforts chronicled in this book and credited with coining the term…Lean Manufacturing

LeanCurrent Condition

• Overproduction

• Waiting

• Transportation

• Non-Value Added Processing

• Inventory

• Defects

• Motion

• Underutilized People

Elimination of Waste

LeanCurrent Condition

Kaizen (Process Improvement) Events Schedule

Shortcomings of our approachCurrent Condition

• The energy and the gains are difficult to sustain and as a result of entropy.

• There is not enough activity to facilitate a learning experience across the organization.

What is missing in our approach?The element of the Toyota Production System that has been difficult to recognize is the daily management and coaching routine that maintains focus and energy on the goal of improvement.

There is activity at every process daily to advance the process toward the vision.

image from Lean Lexicon book

What is a KATA?

A routine that is practiced deliberately in effort to make its pattern a habit.

National League Champs!

Practice - Practice - Practice

Little League Baseball Team Picture Removed from Slide

The Talent Codeby Daniel Coyle

The right kind of practice moves us toward perfection

TOYOTA KATA2 Kata Routines

Improvement Kata – How we Improve

Coaching Kata – How we support and maintain the Improvement Kata

IMPROVEMENT KATAA Continuous Improvement routine that occurs daily at all processes in the organization, to move each process toward its long-term vision or performance challenge. (+ develop capacity and focus)

The way forward is iterative & experimenting, aimed at a desired condition that we don’t yet know how we will achieve.

Copyright: Mike Rother – Improvement KATA Handbook

COACHING KATAA routine that occurs daily in conjunction with the Improvement Kata to support and maintain it.

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Learn More about Toyota Kata!Attend a UT-CIS 1-day Toyota Kata Workshop:

• Nashville – November 12, 2013• Knoxville – January 28, 2014• Memphis – January 30, 2014• Cookeville – February 11, 2014• Jackson – March 11, 2014• Johnson City – May 20, 2014

Read the Toyota Kata Book!

Visit Mike Rother’s Toyota Kata Homepage: http://www-personal.umich.edu/~mrother/Homepage.html

Visit Lean Enterprise Institute’s Kata Page: http://www.lean.org/kata/

Join the Toyota Kata Learning Network on LinkedIn: http://www.linkedin.com/groups/Toyota-Kata-Learning-Network-TKLNin-4012704

Contact me: Dwaine Raper, UT-Center for Industrial Services phone: 423-741-4898 e-mail: dwaine.raper@tennessee.edu

Questions?

Dwaine RaperSolutions ConsultantNortheast TN423.741.4898dwaine.raper@tennessee.eduwww.cis.tennessee.edu