Business Management / Lean Methods & Implementation S O L The biggest competitive advantage an organization can achieve comes from the T E synergies created by employees skilled in enhancing organizational dynamics. R O The 7 Kata: Toyota Kata, TWI, and Lean Training supplies time-tested tools • and advice to help readers adapt to changing conditions and outcompete B their rivals. It explains why a mix of the skill sets that Training Within Industry O U (TWI) and the Toyota kata (behavior patterns) teach is the ideal recipe to boost T The organizational synergies and enhance any Lean transformation. I E R Bridging the kata/TWI nexus, the book lays out a roadmap for Lean success. It devotes a chapter to each of the seven kata and suggests possible courses of action dependent on your organization’s strengths and constraints. Bringing together valuable information on many of the disjointed Lean practices, it explains key Lean concepts, including gemba walks, genchi gembutsu, and PDCA. After introducing kata, it reveals the different kata inherent in the three major TWI TT courses and the TWI Job Safety course. It illustrates the value stream analysis HH Kata relationship to the kata and the kata relationship to TWI. It also demonstrates how to use kata to solve the problems identified in your value stream analysis EE while simultaneously conditioning your employees’ adaptive thinking patterns. Supplying a clear understanding of exactly where the seven kata apply in your Lean journey, the authors include helpful guidelines for coaching a kata. They also highlight mistakes they have experienced or witnessed so you can avoid KK Toyota Kata, the same pitfalls. As globalism continues to make management’s organiza- AA tional skills a competitive differentiator, this book provides you with the tools TT to use the seven kata to place your organization on a discernible path toward TWI, and operational excellence. AA Lean Training K13797 ISBN: 978-1-4398-8077-7 90000 CONRAD SOLTERO www.crcpress.com 9 781439 880777 PATRICE BOUTIER www.productivitypress.com K13797 cvr mech.indd 1 5/18/12 9:25 AM Th7e — Kata Toyota Kata, TWI, and Lean Training CONRAD SOLTERO PATRICE BOUTIER CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2012 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Version Date: 20120501 International Standard Book Number-13: 978-1-4398-8078-4 (eBook - PDF) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the valid- ity of all materials or the consequences of their use. 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Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com Contents Foreword.......................................................................................... vii Patrick.Graupp Foreword........................................................................................... ix Robert.J..Wrona Foreword.........................................................................................xiii Jim.Huntzinger Preface............................................................................................ xvii Acknowledgments.........................................................................xxiii 1 Weapons.for.the.Economic.Warrior..............................................1 1.1 Skills, Not Tools ..................................................................................1 1.2 Toyota’s Connective Tissue ................................................................2 1.3 Skills of the Warrior ...........................................................................3 1.4 Training within Industry’s Japanese Connection ..............................6 1.5 Lean’s Formula: Syncretism and Ritual ..............................................7 1.6 Getting Started ..................................................................................10 1.7 A Word of Warning to Top Management ........................................12 2 Improvement.Kata:.Kaizen.........................................................13 2.1 Means to an End—Kata and Kaizen ...............................................13 2.2 Value Stream Analysis ......................................................................15 2.3 Improvement Kata Method ..............................................................18 2.3.1 Coaching the Improvement Kata ..........................................18 2.3.2 Five Questions .......................................................................19 2.4 Yokoten .............................................................................................27 2.5 Conclusions .......................................................................................28 3 Nested.Job.Instruction.Kata:.Learn.to.Teach..............................29 3.1 Training to Instruct ...........................................................................31 3.1.1 On-the-Job Training Development .......................................32 iii iv  ◾  Contents 3.1.2 Power of One-on-One ..........................................................36 3.1.3 Quintessential Standard—Demonstrated ..............................36 3.2 Nested Kata ......................................................................................37 3.2.1 Important Step (IS) Kata ........................................................37 3.2.2 Key Point (KP) Kata...............................................................40 3.2.3 Kata for How to Get Ready to Instruct .................................41 3.3 From Training Course to Kata .........................................................45 3.4 Conclusions .......................................................................................47 4 Coaching.Kata:.Teaching.to.Learn..............................................49 4.1 Introduction ......................................................................................49 4.2 Preceptor Development ....................................................................50 4.3 Coaching Philosophy ........................................................................52 4.4 Coaching ...........................................................................................55 4.5 Coaching and Improvement Kata Card Revision ............................58 4.6 Developing a Kata Culture Using a Training Timetable .................63 4.6.1 JR Connection ........................................................................66 4.6.2 Coaching the Problem-Solving Kata .....................................68 4.7 Conclusion ........................................................................................69 5 Problem-Solving.Kata:.Seek.to.Understand.Kata.......................71 5.1 Unconsciously Neglecting Problems ................................................71 5.2 PS Kata ..............................................................................................72 5.3 PS Kata Family ..................................................................................78 5.4 Training within Industry Problem-Solving Training .......................80 5.5 Six Sigma in Context ........................................................................81 5.6 Conclusions .......................................................................................82 6 Job.Relations.Kata:.The.Cultural.Fortifier..................................85 6.1 Collaboration and Conciliation ........................................................85 6.2 Practicing the JR Kata .......................................................................86 6.3 Need for Coaching ...........................................................................87 6.3.1 Coaching the JR Kata ............................................................87 6.4 Practicing the JR Kata .......................................................................88 6.4.1 Step 1 .....................................................................................91 6.4.2 Step 2 .....................................................................................92 6.4.3 Step 3 .....................................................................................92 6.4.4 Step 4 .....................................................................................93 6.4.5 Reflection ...............................................................................93 6.5 Foundations for Good Relations ......................................................94 Contents  ◾  v 6.6 JR Kata and A3 Thinking .................................................................94 6.5 Conclusion ........................................................................................95 7 Job.Safety.Kata:.The.Duplex.Kata..............................................97 7.1 JS Improvement Kata ........................................................................97 7.1.1 Step 1 ...................................................................................100 7.1.2 Observations ........................................................................107 7.2 JS Problem-Solving Kata .................................................................108 7.2.1 Step 2 ...................................................................................109 7.2.2 Step 3 ...................................................................................110 7.2.3 Step 4 ...................................................................................111 7.3 JI Kata Connection .........................................................................112 7.4 A New 5-Why? ................................................................................113 7.5 Conclusions .....................................................................................115 8 Job.Methods.Kata:.Kipling’s.Kata.............................................117 8.1 Introduction ....................................................................................117 8.2 Relationship of the Improvement and JM Kata .............................118 8.3 Coaching .........................................................................................119 8.4 Proposals and the Nascent Teian Program ....................................119 8.5 JM Kata ...........................................................................................120 8.5.1 JM Analysis ..........................................................................120 8.5.2 Nemawashi and A3 Thinking .............................................125 8.5.3 Continuous Improvement ....................................................127 8.6 Conclusion ......................................................................................127 9 Submit.to.the.Kata....................................................................129 9.1 First Things First .............................................................................131 9.2 Adaptive Learning ..........................................................................133 9.3 Conclusion ......................................................................................136 Appendix:.Lean.Training.Within.Industry.(TWI).Timeline............137 References.......................................................................................149 Biographies.....................................................................................157 Foreword Conrad Soltero and Patrice Boutier are two of the earliest and most con- sistently diligent students, practitioners, and teachers of the TWI methods. Through their hard work and steadfastness they have made a major contri- bution to the resurgence of TWI in the United States. Their experience with TWI over the past ten years clearly shows in this work—most notably in how they are able to adroitly place TWI into the larger realm of Lean prac- tice and what the world has learned about Lean since the TWI programs were first developed in the 1940s. By looking at the TWI methods, JI/JM/JR and JS, as everyday practices that become as much a part of “who we are” than simply “what we do,” they show the continuing power of these methods to alter ourselves and improve our daily work. Although each of the TWI methodologies can stand on its own, through their integrated view of these methods as kata or human practice, Soltero and Boutier show how the methods comple- ment each other, as well as the later Lean approaches, and provide a holis- tic approach to frontline leadership. It is in this well-rounded approach to skills development that we begin to perceive, as the authors clearly show, an image of a learning organization that can tap into its true human potential. Patrick.Graupp TWI Institute Senior Master Trainer Author of The TWI Workbook: Essential Skills for Supervisors Implementing TWI: Creating and Managing a Skills-Based Culture and Getting to Standard Work in Health Care: Using TWI to Create a Foundation for Quality Care vii