1. Lean Management + Kata Training
Learning Lean practicing with Lean Kata Trainer
January 2017
1
www.focuslean.com
2. • Lean Management current situation
• What Kata is?
• The Improvement Kata model.
• Student training goals.
• Methodology = Gamification = Lean Kata Trainer.
Lean Management + Kata
Contents
• 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.
2
3. Lean Management + Kata
Lean Management current situation
20th century
Periodic
21th century
Daily
LEAN MANAGEMENT
3
SCIENTIFIC
THINKING
Lean group
Eliminate waste
Toyota based
must do
Managers
Strategic objectives
We do what we
must do
4. Lean Management + Kata
We have learned Lean as a set of recipes and tools that we necessarily
want to apply in our processes...
AND THIS IS NOT ALWAYS POSSIBLE
We need something MORE, we need to learn to use:
4
THE SCIENTIFIC THINKING
We need something MORE, we need to learn to use:
To ensure that everyone in an organization learn how to improve any
process.
5. Lean Management + Kata
“Let´s try itandsee"
SCIENTIFIC THINKING
It 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.
5
What we
expect
to happen
What
actually
happened
Learning
6. Lean Management + Kata
Visible
Lean tools and techniques to
improve quality, cost and
delivery
Where we are focused in Lean now
6
Less
Visible
• 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
7. Lean Management + Kata
4 INGREDIENTS FOR ACQUIRING NEW SKILLS
The following ingredients help us rewire our brain (new neural circuits) to
acquire new skills & mindset.
k
COACHING
STARTER
KATA l
Structured routines
7
This is
how you
do it
j FREQUENT
PRACTICE
MASTERY m
Corrective feedback
to ensure the Learner
practices the right
patterns
Growing self efficacy
"I'm getting better at this"
Structured routines
for beginners
to practice
fundamentals
A little every day
By Mike Rother
8. 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?
8
Combining a scientific pattern with structured practice
routines (Kata) develops effective problem solvers.
By Mike Rother
Science + Kata = Problem Solving Skill
9. Lean Management + Kata
KATA ARE LIKE ROCKET ENGINES
KATA
9
They help you get started
10. Lean Management + Kata
We 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 or
Challenge
3
10
By Mike Rother
Conduct Experiments
to get thereGrasp the
Current
Condition
Establish
your Next
Target
Condition
1
2 4
The Improvement Kata model comes from research into how Toyota manages people,
which is summarized in the book “Toyota Kata”
11. Lean Management + Kata
THE SCIENTIFIC LEARNING CYCLE
The scientific process of acquiring knowledge
PREDICTION
Testable
EVALUATE
Adjust based on
what you learn PLANACT
11
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
ACTION
Conduct the
experiment
what you learn
EVIDENCE
Collect facts and data
PLAN
DO
1
23
4
CHECK
(Study)
ACT
12. Lean Management + Kata
DO YOUR TESTS IN THE
"EXPERIMENTING ZONE"
A measureable
Target Condition
with achieve-by date
Current
Condition
12
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.
13. Lean Management + Kata
BUT THERE IS A PROBLEM
No matter how good it is, just explaining a model
doesn't generate new ways of thinking and acting.
Hoping to create different behavior by explaining
or trying to convince generally doesn't work.
13
14. Lean Management + Kata
Kata are also practice routines that
help you adopt new ways of acting
and thinking.
THE ROLE OF PRACTICE ROUTINES
14This is where brain
science comes in
15. 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.
Lean Management + Kata
• 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.
15
17. Lean Management + Kata
To carry out this training of the improvement Kata and coaching Kata
for processes, has been designed a gamification digital product :
Lean Kata Trainer
17
18. 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.
Lean Management + Kata
• 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.
18
19. • 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:
Lean Management + Kata
• 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.
19
20. 5-26 October 2016: courses in the Carlos III Industrial Engineering University (Madrid)
Lean Management + Kata
20
21. Lean Management + Kata
21
https://www.youtube.com/watch?v=YKJ9I8eiJp8
22. Lean Management + Kata
k LEARN
COACHING
CREATE
KATA l
THE Lean Kata Trainer CYCLE
22
LEARNAND
PRACTICE
BECOME A
MASTER
m
This is
how you
do it
j
23. Processes
Lean Kata Trainer (LKT) videogame estructure
Lean Management + Kata
LUCOS
Customer RESULTS
ProductsThe context
Processes
23
The game
N1 N2 N3 N4 N5
Lean
Management
KATA
Game Levels
The team
The ChallengeThe Challenge
Current
Management
System
24. 24
Lean Management + Kata
The Lucos team
General Director
The processThe process
Financial Director Team Leader
24
General Director
The processThe process
Financial Director Team Leader
The Customer
25. Lean Management + Kata
The Kata method in the LKT
The Challenge
25
By Mike Rother
26. LKT videogame levels
Lean Management + KataimprovementKATA
Pull System Poka Yoke
N4 Kanban
Kanban
Batch size = 1
Demand variability Supermarket
Model
Pull
N5 MTO*
*Make to Order
New products
New
Product
Level Scenario Screen Lean Tools Target Condition
26
N1
improvementKATA
Job cells
Work in cells
Batches planning
Zero breakdowns
SMED
Process
Stabilization
N2 Flow
Work in flow
Balanced work
Standarization
Jidoka
Work in
flow
N3 Pull
Pull System
WIP limit
Poka Yoke Pull
Process
Andon
27. 27
Lean Management + Kata
The 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.
28. 28
Lean Management + Kata
The achievement in the LKT
Lean
Management
New
Products
Supermarket
Pull Costs
New
Markets
New
Customers
Q
28
Flow
Process
Stabilization
Current
Situation
Quality
29. To whom it is addressed
This 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
Lean Management + Kata
• 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.
29
30. • 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 trainer
Lean 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.
30
