toyota kata direct - lean frontiers...toyota kata direct lean frontiers, inc. twi institute katacon...

Toyota Kata Direct

Lean Frontiers, Inc. TWI Institute KataCon & TWI Summit Feb. 18-22, 2019www.leanfrontiers.com www.twi-institute.org www.leanfrontiers.com/skillsweek 1

Toyota Kata Direct

Establish the (Next) Target Condition

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Step 3 Establish the first Target Condition (and the next)

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Toyota Kata Direct


The Linear View

Thanks to Mike Rother

WE ARE HERE!

Professional science:The current research question –what part of the whole are the facts suggestingwe need to better understand next?

A Target condition = The research question

• In the ImprovementKata, Establishing the Target Condition is the equivalent in professional science to the current research question – what part ofthe whole are the factssuggesting we need to better understand next?

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Toyota Kata Direct


It’s a Target Condition

• Markers along the way

• A translation of whatthe japanese call a ”Target”

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Conduct Experimentsto get thereGrasp the

CurrentCondition

Establish your Next

TargetCondition

Get the Direction orChallenge

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It’s a Target Condition

• Key word is condition

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Conduct Experimentsto get thereGrasp the

CurrentCondition

Establish your Next

TargetCondition


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rulle

ställtiden

STANSNING SVETS & MONT. LEVERANS200 TON

dagligaorder

6 veckorsprognos

dagliga order

dagligaorder

1 xdag

Packning

S/T = 1 timmeC/T = 1 sek

C/T = 55 sekTakt = 60 sek

1,5 dagarledtid i produktion = 5 dagar

värde-höjning = 166 sek

1 sekund1,5 dagar

165 sekunder2 dagar

Swesteel AB

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omställningi svetsen

up-time isvetsningen

Totalt<168 sek.

PRODUKTIONSPLANERING

MPS

60

1,5 dagar

20

rulle

rullar

OXOX 2020

20

43

21

2 dagar

90/60/30 darsprognoser

18.400 st/mån-12.000 ”V”-6.400 ”H”

2 skift

Låda = 20 st

Scavos ABMontering

920 st/dag

TAKT =460 min460 st

= 60 sek

SATS = 60 sek x 20 st =20 min

HVVHVVHVV

46 lådor

Källa: M. Rother & J. Shook (2005)

Slingbildagligen

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Toyota Kata Direct


A “state” beyond our current “knowhow”

• A Target Condition is a “state” beyond ourcurrent “knowhow” and thus will require us to iterate our way through the “grey zone”, a zone of uncertainty.

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Brings out actual NEEDS

• A Target Condition ensures peoples efforts arefocused on ACTUAL NEEDS rather than ideaswhich are often guesses arising from whatCAN be done.”

• A Target Condition helps teamwork because it is forward looking and begs the question“What do we all NEED to focus on now?”

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Toyota Kata Direct


You don’t do an actionplan!

• You don’t “plan yourwhole way” to a Target Condition – No plan willcover everything, and that is OK.

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Obstacles surface

• A Target Condition directs you to the obstaclesNEEDED to be worked on.

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Conduct Experimentsto get there

Grasp the Current

Condition

Establish your Next

TargetCondition

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Obstacles are the real problems you NEED to work on to move forward!


Obstacles

Toyota Kata Direct


Case study, Current condition

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Target Condition: ”One side at a time”

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Toyota Kata Direct


Obstacles came up!

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Layoutissues Toolsissues Fixtures

The destination…..

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Toyota Kata Direct


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Thank you for listening!

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