Lecture 3a

KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
01
TOYOTA KATA
Establishing the
Target Condition

KATA
© 2016 Jidoka®
02
The Improvement Kata
ESTABLISH THE TARGET CONDITION
Practice
this
Routine
For reference
see:
Chapter
5

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© 2016 Jidoka®
03
We are here We want to be here

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© 2016 Jidoka®
04
ATARGET CONDITION ENABLESTEAMWORK
With aTarget Condition
Let’s try and operate in the
Target condition and see what
are our real obstacles?
How many obstacle can we see?
“Let’s try your idea”… “But, I like
your idea better
What do we need to try to
operate in the Target Condition
?
PDCA/PDSA is possible!
NoTarget Condition
Who’s opinion is right?
How do we prioritize our
obstacles?
What is the real problem?
“I like my idea, not
yours”…”And I like my idea”
PDCA/PDSA is impossible

KATA
© 2016 Jidoka®
05
Process Metrics vs Outcome Metrics
Many people have difficulty understanding the relationship and differences between a
Process Metric and an Outcome Metrics. The concept they fail to understand is twofold:
1. Process Metrics are measurements in real time. It is however possible to consider a
measurement either at a certain point in time past the beginning of the process or maybe
at the end of the day. Process Metrics are metrics that you can gather “in the moment”
• Example are such a construction of a run chart in the previous slides on lowest
repeatable process cycle time or the variation from cycle to cycle.
• Another example is rework. We can measure the first pass yield (FPY for the day at
any point in the shift and know at what rate we are having to rework
2. Process Metrics affect or many times determine the values we get as Outcome Metrics.
Many times we refer to the Process Metric as the “lever” that controls the Outcome Metric.
• Example: An Outcome Metric for a pot of boiling water is determined by the Process
Metric of the stove burner element.
Process Metric =
Knob Set at 7
Outcome Metric = Temperature
of Water is 100oC

KATA
© 2016 Jidoka®
06
Relational Analogies of Process Characteristics,
Process Metrics, and Outcome Metrics...
• Characteristic – a feature or quality
typically belonging to a person, place,
or thing and serving to identify it
• Attribute – to consider as a quality or
characteristic of the person, thing,
group, etc.
Describes how we play the game
PROCESS CHARACTERISTIC
OR ATTRIBUTE
• Process Metrics - Standards of
measurement by which efficiency,
performance, progress, or quality of a
plan, process, or product can be
assessed
Process Metrics are key indicators from
within the process itself that suggest what
can be expected with the Outcome
Metrics… Process Metrics have an indirect
(or direct) impact on Outcome Metrics.
How we are performing within the game
PROCESS METRICS
• Outcome Metrics - Determination and
evaluation of the results of an activity,
plan, process, or program and their
comparison with the intended or
projected results
Outcome Metrics are final scores that
provide clear and concise understanding
as to how the process is performing
against the standard or target condition.
The score of the game
OUTCOME METRICS
Definitions & Descriptions
We are a good free throw shooting team –
91% (free throw shooting percentage). We
set plays to drive into the lane and draw
contact (foul) from the opposing team to
get a high number of free throw attempts
in the game, putting more points on he
board, and a better chance at winning the
game.
OR ATTRIBUTE
• Fouls drawn
• Shooting Fouls
• Floor Fouls
• Number of Free Throw attempts
• Free Throw shooting percentage
• Free Throw shooting
percentage on front end of 1 &
1
PROCESS METRICS
• Final Score of the game
• Win / Loss record
OUTCOME METRICS
A Sports Analogy
We execute to schedule on all
recommended preventative and predictive
maintenance activities on our press. For
PM work that can’t be done with the press
running or in setup, we allot 4 hours
(planned down time) on Mondays for PM
activity.
OR ATTRIBUTE
• Overdue PM Work Orders
• Unplanned Maintenance hours
(reactive – break downs)
PROCESS METRICS
• Press Up Time Percentage
OUTCOME METRICS
ACME Gear, CO. Example

KATA
© 2016 Jidoka®
07
Target vsTarget Condition
Process Characteristics: Indoor or Outdoor?
TheTarget = Bullseye
Productivity,Scrap, Infection rate
TheTarget 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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© 2016 Jidoka®
08
Target vsTarget Condition
Large competition or Small local competition

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© 2016 Jidoka®
09
Process Characteristic = WIND

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10
Process Characteristic =
5 C Cold vs Hot 45 C

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11
Sunny vs Dusk vs Rain?

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© 2016 Jidoka®
12
Traditional vs Nontraditional

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© 2016 Jidoka®
13
Process Characteristic = Equipment

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14
WHAT INFORMATION IS IN ATARGET
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, these are
decided from
the “Bottom Up”
First

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© 2016 Jidoka®
15
The following slides are example forms of proven ways
to establish the next Target Condition

KATA
© 2016 Jidoka®
16
TARGET CONDITIONS RECORD (ONE PAGE PER TARGET CONDITION
PERIOD)
KATA: CHALLENGE(include details, not just the challenge name):
START DATE OF NEW TARGET CONDITION PERIOD:
_____________
END DATE OF NEW TARGET CONDITION PERIOD:
______________
COACHING CYCLE (BETWEEN COACH & 2ND COACH) DATE: _____ TIME:
_____
COACH: _________ 2ND
COACH: _________ LEARNER:
_________
TARGET CONDITION THEME
FUTURE STATE DETAILS
(WHAT DO YOU EXPECT?)
What happened?
(observe closely)
What did you learn?
(what you expected? / what happened?)
COACHING CYCLE / EXPERIEMENTS
FACTS & DATA?
WAS AN OBSTACLE
ELIMINATED?
WHAT IMPROVEMENTS
WERE MADE…WHAT
STANDARDS WERE PUT IN
PLACE?
WHAT ARE THE METRIC
AND CAHRACTERISTIC
VALUES COMPARED TO
WHAT YOU EXPECTED…LIST
THEM OUT … WHAT IS THE
% OF ATTAINMENT?
ABOUT THE PROCESS?
ABOUT THE OBSTACLES?
ABOUT SCIENTIFIC
PROBLEM SOLVING?
ABOUT SETTING TARGET
CONDITIONS FOR THIS
CHALLENGE?
WHAT SPECIFICALLY WILL
CHANGE FROM THE CURRENT
CONDITION?
WHAT ARE THE METRICS AND
CHARACTERISTICS FOR THE
KATA (LIST THEM OUT)…
WHAT ARE THE CURRENT
VALUES TODAY, AND WHAT
WILL THE VALUES BE AT THE
END OF THE TARGET
CONDITION?
WHAT WILL BE THE
FOCUS FOR THIS TARGET
CONDITION PERIOD?
WHAT OBSTACLE ARE
YOU FOCUSED ON?

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© 2016 Jidoka®
17
TARGET CONDITIONS RECORD (ONE PAGE PER TARGET CONDITION PERIOD)
START DATE OF NEW TARGET CONDITION PERIOD: END DATE OF NEW TARGET CONDITION PERIOD:
COACHING CYCLE (BETWEEN COACH & 2ND COACH) DATE: TIME: COACH: 2ND
COACH: LEARNER:
TARGET CONDITION
THEME
What happened?
(observe closely)
What did you learn?
(what you expected? / what
happened?)
COACHING CYCLE
/ EXPERIEMENTS
COACH: LEARNER:
TARGET CONDITION
THEME
What happened?
(observe closely)
What did you learn?
happened?)
COACHING CYCLE /
EXPERIEMENTS
A B
C

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© 2016 Jidoka®
18
COACHING CYCLE (BETWEEN COACH & 2ND COACH) DATE: TIME: COACH: 2ND COACH: LEARNER:
TARGET CONDITION
THEME
What happened?
(observe closely)
What did you learn?
happened?)
First define your TC
theme and
obstacles
Next what will the TC
Process Characteristics
and Metrics look like
COACHING CYCLE /
EXPERIEMENTS
Once the TC has ended,
evaluate what
happened. What
standards are in place?
What did you learn over
the past 2-4 weeks?
What would you have
done differently?
COACH: LEARNER:
TARGET CONDITION
THEME
What happened?
(observe closely)
What did you learn?
happened?)
Define your next TC
theme and obstacles
What will TC #2 look like?
What will the Process
Characteristics and
Metrics ?
COACHING CYCLE /
EXPERIEMENTS

KATA
© 2016 Jidoka®
19
Date: 3 July Regional Qualifications
• 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 68m
Process Metrics
• 10 point/rd. scoring, 10 Targets/rd.
Outcome Metrics
• Highest round scores win 3 medals, Gold,
Silver, or Bronze
Achieve by: 3 July
• 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 cells
Process 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 Condition
for Archery
Target Condition for
Manufacturing

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© 2016 Jidoka®
20
Target Condition Side of the Storyboard –
Healthcare, Emergency Dept.
Achieve by: 3 July
• Capacity of 215 patients in 24 hours
• 45 beds, Medical screening and Trauma
• No. of Nurses = 12 on 0700-1500, 18 on 1500-2300, 14 on 2300-0700
• Two 15 min breaks, One 30 min lunch
Process Metrics
• Labs Turn around time (TAT):
• Blood panels = 30 min; Urinalysis = 25 min; Radiology = 20 min
Outcome Metrics
• Patient Length of Stay (LOS) to d/c < 220 min
• Patient Length of Stay (LOS) to admit < 260 min
EMS arrives
with
patient
Trauma or
Medical
Screening?
Medical
Screening
Exam -
Physician
Labs order
by
Physician
Physician
Diagnosis &
Treatment
by Nurse
Discharged
or admitted

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© 2016 Jidoka®
21
Target Condition
Achieve by: 06.10.2016
Current Condition
Process Metrics Process Metrics
Outcome Metrics Outcome Metrics
F/A - Pack
Mill 8
Mill 7
Mill 6
Mill 5
Mill 4
Mill 3
Mill 2
Mill 1
CNC 2
CNC 1
Shaper 6
Shaper 5
Shaper 4
Shaper 3
Shaper 2
Shaper 1
Hob 18
Hob 17
Hob 16
Hob 15
Hob 14
Hob 13
Hob 12
Hob 11
Hob 10
Hob 9
Hob 8
Hob 7
Hob 6
Hob 5
Hob 4
Hob 3
Hob 2
Hob 1
Hob 0
Hob 1
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
OTHER PROCESS METRICS:
Mill Reliability is 80%
Overtime is due to machine reliability at Turning Mills 1,7, & 8
NOTES AND OBSERVATIONS
PROCESS CHARACTERISTICS:
We have excess capacity and high variation in machine cycle
with our Hob Machines. Hob 18 cycle time exceeds Takt Time
We have excess capacity and high variation in machine cycle
with our Turning Mill Machines.
PPLH = 27.5
Scrap = 6.7%
OverTime = 8%
First Pass Yield = 93%
Exit Cycle Var(Pack) = 10 s +/- 12%
Hob 18 Lowest Repeatable Hi Var = +195%
Lo Var = - 24%= 14 seconds
Takt Time = 12.3 seconds
Planned Cycle Time= 10.5 Seconds
Number of Shifts = 3
Number of Operators = 10
CURRENT CONDITION SUMMARY SHEET
Outcome Metrics (See Charts)
Process Stability:
First Pass Yield > 95%
Mill Reliability > 85%
PPLH > 37.5
Scrap < 5%
Overtime < 10%
Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less
floor space, operating 2 shifts with 50% of the machinery, so we can achieve:
50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell
Obstacle
1
2
3
4
5
Workload on operators
Scrap
OBSTACLES PARKING LOT
How will you measure that?
Less number of Hobs
Less number of Turning Mills

Lecture 3a

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Lecture 3a