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Improvement Kata & Coaching Kata Experience 1 © Mike Rother Scott Wade Simmons & Associates, LLC Copyright 2018

Improvement Kata & Coaching Kata Experience...Improvement Kata and Coaching Kata. “A systematic routine for developing people, improving processes, and achieving business results.”

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  • Improvement Kata & Coaching Kata Experience

    1© Mike Rother Scott Wade Simmons & Associates, LLC Copyright 2018

  • It’s All About The People

    2Scott Wade Simmons & Associates, LLC Copyright 2018

  • For this exercise we'll build this 15-piece puzzleseveral times and practice the Improvement Pattern

    Improvement Kata & Coaching Kata Experience

    3Scott Wade Simmons & Associates, LLC Copyright 2018

  • 1. Take the puzzle out of the bag and study the picture for 30 seconds2. Remove the puzzle pieces from the frame, place them upside down

    on the table3. Put the frame back in the bag

    Do the entire exercise without thepuzzle framePut the Frame Aside

    GETTING STARTED

    4Scott Wade Simmons & Associates, LLC Copyright 2018

  • LET’S PRACTICE• All team members should participate• Get your stopwatch app ready

    • Identify one team member to start and stop the timer at the beginning and end of the cycle

    • We’ll run four rounds of practice• Track time on Current Condition sheet

    5Scott Wade Simmons & Associates, LLC Copyright 2018

  • (1) START Position- Puzzle pieces shuffled in random order – rule #1- Pieces face down in one stack – rule #2- Hands flat on the table- No talking, you're ready to go

    (2) All Teams Start Together- Instructor calls "START"- Build the puzzle (talking allowed)

    (3) Don't Write on the Puzzle – rule #3

    (4) Puzzle Pieces must Remain Face Down Until Timer Starts – rule #4

    (5) Go!!!

    LET’S PRACTICE

    6Scott Wade Simmons & Associates, LLC Copyright 2018

  • Make Improvements!

    • Between rounds 2, 3, and 4, please discuss improvement options as a team

    • Choose as many improvements as you want to make each round

    • Run rounds 2, 3, and 4• After each round, document your build time on the

    Current Condition sheet• After round 4, write down how you built the puzzle,

    i.e., Who did what task, in what order

    7Scott Wade Simmons & Associates, LLC Copyright 2018

  • Improvement Kata & Coaching KataNow we begin………

    Conduct Experimentsto get there

    (PDCA)

    Grasp the Current

    Condition

    Establish your Next

    TargetCondition

    Get the Direction orChallenge

    8Scott Wade Simmons & Associates, LLC Copyright 2018

  • TRAINING PURPOSE

    • Use a classroom instruction and a simulation to teach you the patterns for improvement & coaching

    • Present, practice, discuss - repeats• Increase awareness• Hopefully…..you’ll want to know more!

    The purpose of this training is to teach a basic understanding of the Improvement Kata and Coaching Kata. “A systematic routine for developing

    people, improving processes, and achieving business results.”

    9Scott Wade Simmons & Associates, LLC Copyright 2018

  • Any complex performance requires skill.

    • We develop new skill through practice.

    • Long time-gaps between practice sessions isn’t effective for learning. Daily is a good frequency.

    • We need correction (Coaching). We are not good at self-feedback to understand where we are deviating from good practice.

    ABOUT SKILL-DEVELOPMENT

    10© Mike Rother Scott Wade Simmons & Associates, LLC Copyright 2018

  • Let's go through the 4 steps of the Improvement Kata

    GETTING STARTED

    Conduct Experimentsto get there

    (PDCA)

    Grasp the Current

    Condition

    Establish your Next

    TargetCondition

    Get the Direction orChallenge

    1

    2

    3

    4Coach

    11© Mike Rother Scott Wade Simmons & Associates, LLC Copyright 2018

  • Conduct Experimentsto get there

    Grasp the Current

    Condition

    Establish your Next

    TargetCondition

    Get the Direction orChallenge

    1

    STEP 1:UNDERSTAND THE DIRECTION

    Coach

    12© Mike Rother Scott Wade Simmons & Associates, LLC Copyright 2018

  • Step 1:Understand the Direction• Define and document the overarching Challenge

    • We need alignment. Start with the business objectives and cascade downward.

    • How and where does your department affect those objectives?

    • Define and document the Challenge for your department to strive toward.

    • Challenge “by” dates are usually 9 months to 3 years out. You won’t achieve your Challenge right away.

    13Scott Wade Simmons & Associates, LLC Copyright 2018

  • Step 1:Understand the Direction - Puzzle

    Your Challenge“Complete puzzle within Planned Cycle Time

    with 2 people by the end of class”

    Focus Process: Challenge:

    Target ConditionAchieve by:

    Current Condition

    *Take 2 minutes and update your story board with Focus Process and Challenge

    Your Focus Process is: “Puzzle Build”

    14Scott Wade Simmons & Associates, LLC Copyright 2018

  • Conduct Experimentsto get there

    Grasp the Current

    Condition

    Establish your Next

    TargetCondition

    Get the Direction orChallenge

    STEP 2:GRASP THE CURRENT CONDITION

    2Coach

    15© Mike Rother Scott Wade Simmons & Associates, LLC Copyright 2018

  • CC: Process Analysis Pattern

    16© Mike Rother Scott Wade Simmons & Associates, LLC Copyright 2018

  • Net Available TimeAmount of time available in a defined period minus any scheduled breaks, meetings, or other planned downtimeDemandWhat the customer wants in the same defined period of time Planned Cycle Time85% of Takt Time (creates a buffer for unplanned variables)Example: Takt Time = 24780 seconds/300 scopes = 83 secondsPlanned Cycle Time = 83 seconds x 0.85 = 71 seconds

    Takt Time =Time Available

    Customer DemandTAKT TIME

    Your: TT = 15 secondsPc/t = 13 seconds

    Note: In cases when you can't calculate a takt time, you can still set a Designed Takt Time. Simply ask yourself:

    “How often do we want this task to be happening?”

    This demand model can be good enough for starting.

    *Take 1 minute and update your story board

    Add to your Challenge Section

    STEP 2 PACE

    17Scott Wade Simmons & Associates, LLC Copyright 2018

  • • Get to know the process by sketching it (Block Diagram)

    - Show where the people are in the steps- Define the batch sizes at the processing steps?

    - Identify where Work In Process (WIP) accumulates

    DOCUMENT CURRENT PROCESS

    Process Name

    Process Name

    Process Name

    Process Name

    Your Process (Block Diagram)

    People

    WIP

    1-2 pcsBatch sizes

    • Note other details about the current operating pattern- These are not issues seen as good or bad, right or wrong.- They simply describe aspects of the current work pattern.

    - Operator leaves work station every 10th part to replenish inventory- Station 3 made 3 defects out of 50 partsOther Details

    18Scott Wade Simmons & Associates, LLC Copyright 2018

    - Identify & document the process steps in sequence

  • Focus Process: Challenge:

    Target ConditionAchieve by:

    Current Condition

    LET'S DOCUMENT CURRENT CONDITION

    Pace = 42 sec

    *Take 10 minutes and update your story board

    1. Document the operating pattern from round 42. Note the elapsed time as your pace

    Complete puzzle within Planned Cycle Time with 2 people by the end of class (TT = 15 sec

    Pc/t = 13 sec)

    Puzzle Build

    19Scott Wade Simmons & Associates, LLC Copyright 2018

    Everyone grabbedPieces from the Stack & flipped

    AssembledIn a free For all

    • Op 4 quit working – got too crazy

    • Joe stood during the assembly process

    15

  • You are here

    20Scott Wade Simmons & Associates, LLC Copyright 2018

    Six Coaching Questions:

    1. What are you trying to achieve?2. Where are you now?(Relates to Current Condition, Process Analysis step)3. What was your last step? What did you expect? What actually happened? What did you learn?4. What is your next step, and what do you expect?5. Is there anything currently in your way of taking this step?6. How quickly can we see what you’ve learned from taking that step?

  • Coaching Question:

    What is the purpose of a coach?

    21Scott Wade Simmons & Associates, LLC Copyright 2018

    http://www.youtube.com/watch?v=5c_onhzgvcYhttp://www.youtube.com/watch?v=5c_onhzgvcY

  • Coaching

    22Scott Wade Simmons & Associates, LLC Copyright 2018

  • Let's Practice

    • Volunteers needed:• Coach• Learner

    • Go to your story board and practice 2 rounds of coaching

    • 2 Coach/Learner pairs

    23Scott Wade Simmons & Associates, LLC Copyright 2018

  • 10 minute

    24Scott Wade Simmons & Associates, LLC Copyright 2018

  • Conduct Experimentsto get there

    Grasp the Current

    Condition

    Establish your Next

    TargetCondition

    Get the Direction orChallenge

    STEP 3:ESTABLISH YOUR NEXT TARGET CONDITION

    3

    What operating pattern and puzzle build time does your team want to reach in this class period?

    Coach

    25© Mike Rother Scott Wade Simmons & Associates, LLC Copyright 2018

  • Target Condition • Describes a desired future state operating pattern. It is a well-informed

    hypothesis: “If we operate in this way, we will achieve these results.”• It is a description of how we need to operate, NOT how we get there.

    • Once you achieve your Target Condition, then it becomes your new Current Condition

    26

    © Mike Rother

    Scott Wade Simmons & Associates, LLC Copyright 2018

  • Target Condition vs Target

    • Target Condition:• Describes an operating

    pattern that includes:• Steps & sequence• Operators• Inventory (WIP)• People• Batch size• Characteristics• Goal or result

    • Target:• Goal or result• Desired outcome• Score

    Scott Wade Simmons & Associates, LLC Copyright 2018 27© Mike Rother

    Pace = 32 sec

    - Push together to connect puzzle

    Pace = 32 sec

    Take 1/3stack, flip,& assembleleft side

    Take 1/3stack, flip,& assemblemiddle

    Take 1/3stack, flip,& assembleright side

  • • The Target Condition is your next goal on the way to the Challenge. It will take several Target Conditions to achieve your Challenge.

    • You won't know in advance exactly how you will achieve a Target Condition. That's normal and expected. If you do know, please just do it!

    • Your team will have to experiment to achieve the Target Condition!

    • We don’t want to change our Target Condition, but we can add to it.

    KEY POINTS ABOUT:ESTABLISHING YOUR NEXT TARGET CONDITION

    28Scott Wade Simmons & Associates, LLC Copyright 2018

  • Target Condition Pattern

    29© Mike Rother

    Scott Wade Simmons & Associates, LLC Copyright 2018

  • Focus Process: Challenge:

    Target ConditionAchieve by: Today, [x]pm

    Current Condition

    DOCUMENT YOUR TARGET CONDITION OPERATING PATTERN

    - Push together to connect puzzle- Everyone stands

    Pace = 32 sec

    STEP 3:ESTABLISH YOUR NEXT TARGET CONDITION

    *Take 10 minutes and Create your Target Condition

    1. Document the new operating pattern2. Note the pace you are striving for

    NOTE: No practicing building the puzzle to create the Target Condition. Remember we don’t know how we are going achieve it, it describes how we need to operate working towards the Challenge!

    Complete puzzle within Planned Cycle Time with 2 people by the end of class

    Puzzle Build

    (TT = 15 sec Pc/t = 13 sec)

    Take 1/3stack, flip,& assembleleft side

    Take 1/3stack, flip,& assemblemiddle

    Take 1/3stack, flip,& assembleright side

    30

    Pace = 42 sec

    Scott Wade Simmons & Associates, LLC Copyright 2018

    AssembledIn a free For all

    • Op 4 quit working – got too crazy

    • Joe stood during the assembly process

    15

    15

    Everyone grabbedPieces from the Stack & flipped

  • Obstacles• Obstacles prevent us from achieving our target condition

    • Overcoming obstacles means we have developed solutions to problems

    31Scott Wade Simmons & Associates, LLC Copyright 2018

    Apollo 13 Oxygen Tank Redesign

  • 32Scott Wade Simmons & Associates, LLC Copyright 2018

  • Time for a Coaching Cycle!

    Learner's Storyboard

    Learner1st Coach2nd Coach

    Practices the IK

    Practices theCoaching Kata

    Coachesthe 1stCoach

    33© Mike Rother Scott Wade Simmons & Associates, LLC Copyright 2018

  • Conduct Experimentsto get there

    Grasp the Current

    Condition

    Establish your Next

    TargetCondition

    Get the Direction orChallenge

    STEP 4:PDCA TOWARDS THE TARGET CONDITION

    4Coach

    34© Mike Rother Scott Wade Simmons & Associates, LLC Copyright 2018

  • PDCA• Plan Do Check Adjust/Act

    • Small daily steps to reach your Target Condition

    35© Mike Rother Scott Wade Simmons & Associates, LLC Copyright 2018

  • • Guidelines:• Identify obstacles found through running experiments

    • Select one to work on • Use the PDCA Cycle Record to document• Be Specific about your step

    PDCA

    Remember we’re

    Scientists

    36Scott Wade Simmons & Associates, LLC Copyright 2018

  • PDCA Cycles Record

    Scott Wade Simmons & Associates, LLC Copyright 2018 37

    PDCA CYCLES RECORDObstacle:

    Date, step & metric What do we expect? What happened What we learned

    Learner:Process:

    Coach:

    (Each row = one experiment)

    Do a

    Coac

    hing C

    ycle

    Cond

    uct th

    e Exp

    erime

    nt

    © Mike Rother

    PDCA CYCLES RECORD

    Obstacle:

    Date, step & metric

    What do we expect?

    What happened

    What we learned

    Learner:

    Process:

    Coach:

    (Each row = one experiment)

    Do a Coaching Cycle

    Conduct the Experiment

  • Planning Your Next Experiment

    Scott Wade Simmons & Associates, LLC Copyright 2018 38

    PDCA CYCLES RECORDObstacle:

    Date, step & metric What do we expect? What happened What we learned

    Learner:Process:

    Coach:

    (Each row = one experiment)

    Do a

    Coac

    hing C

    ycle

    Cond

    uct th

    e Exp

    erime

    nt

    Before each round, Fill out your PDCA Cycles Record

    Write down your step (be specific) and what you expect

    © Mike Rother

    PDCA CYCLES RECORD

    Obstacle:

    Date, step & metric

    What do we expect?

    What happened

    What we learned

    Learner:

    Process:

    Coach:

    (Each row = one experiment)

    Do a Coaching Cycle

    Conduct the Experiment

  • Sequence of PDCA Cycles Record

    Scott Wade Simmons & Associates, LLC Copyright 2018 39

    PDCA CYCLES RECORDObstacle:

    Date, step & metric What do we expect? What happened What we learned

    Learner:Process:

    Coach:

    (Each row = one experiment)

    Do a C

    oachin

    g Cycle

    Conduc

    t the Ex

    perime

    nt1 2 3 4 67

    58

    1-2. Plan the experiment: Date, Proposed Step, how it will be measured, and predicted result (expectation).3. Go through a Coaching Cycle. 4. Conduct the experiment.5. Record the facts and data about what actually happened.6. Reflect on the outcome of the experiment by comparing the predicted results with the data. Summarize what was

    learned.7-8. Propose the next experiment (see #1), based on what was learned in the last step.

    © Mike Rother

    Learner Steps Coach Step

    PDCA CYCLES RECORD

    Obstacle:

    Date, step & metric

    What do we expect?

    What happened

    What we learned

    Learner:

    Process:

    Coach:

    (Each row = one experiment)

    Do a Coaching Cycle

    Conduct the Experiment

  • You are now here

    40© Mike Rother Scott Wade Simmons & Associates, LLC Copyright 2018

  • 41Scott Wade Simmons & Associates, LLC Copyright 2018

    PDCA CYCLES RECORDObstacle:

    Date, step & metric What do we expect? What happened What we learned

    Learner:Process:

    Coach:

    (Each row = one experiment)

    Do a

    Coa

    chin

    g Cy

    cleCo

    nduc

    t the

    Exp

    erim

    ent

    PDCA CYCLES RECORD

    Obstacle:

    Date, step & metric

    What do we expect?

    What happened

    What we learned

    Learner:

    Process:

    Coach:

    (Each row = one experiment)

    Do a Coaching Cycle

    Conduct the Experiment

  • Let’s incorporate the Coaching

    pattern into your PDCA

    experiments!

    42Scott Wade Simmons & Associates, LLC Copyright 2018

  • PLANNING YOUR NEXT EXPERIMENT

    Fill out your PDCA Cycle Record

    Record This Step

    1. Take 5 minutes to develop what you expect when you “Run to the Target Condition”2. Then, run your experiment! 3. Record your results, what you learned, and record your obstacles!4. Then, determine your next step and what you expect5. Do a Coaching Cycle

    43Scott Wade Simmons & Associates, LLC Copyright 2018

    PDCA CYCLES RECORDObstacle:

    Date, step & metric What do we expect? What happened What we learned

    Learner:Process:

    Coach:

    (Each row = one experiment)

    Do a

    Coac

    hing C

    ycle

    Cond

    uct t

    he Ex

    perim

    ent

    Run to the Target Condition

    PDCA CYCLES RECORD

    Obstacle:

    Date, step & metric

    What do we expect?

    What happened

    What we learned

    Learner:

    Process:

    Coach:

    (Each row = one experiment)

    Do a Coaching Cycle

    Conduct the Experiment

  • FINAL KEY POINTS1. Alignment through the Challenge

    - No more “whack a mole” or “random acts of improvement”

    2. The IK/CK is all about people developing critical problem solving skills. This is the primary result!3. Be a Learner first. Resist the urge to jump into the Coach role (trust me, you’re not ready).4. The Coaches role is to “teach the pattern of the IK and CK as we achieve extraordinary results”5. Follow the IK and CK pattern exactly, (for around a year).

    Scott Wade Simmons & Associates, LLC Copyright 2018 44

    Improvement Kata & Coaching Kata ExperienceIt’s All About The PeopleImprovement Kata & Coaching Kata ExperienceSlide Number 4LET’S PRACTICELET’S PRACTICEMake Improvements! Improvement Kata & Coaching KataSlide Number 9Slide Number 10Slide Number 11Slide Number 12Step 1:�Understand the DirectionStep 1:�Understand the Direction - PuzzleSlide Number 15CC: Process Analysis PatternSlide Number 17Slide Number 18Slide Number 19Slide Number 20Coaching Question:CoachingLet's Practice10 minuteSlide Number 25Target Condition Target Condition vs TargetSlide Number 28Target Condition PatternSlide Number 30ObstaclesSlide Number 32Time for a Coaching Cycle!Slide Number 34PDCASlide Number 36PDCA Cycles RecordPlanning Your Next ExperimentSequence of PDCA Cycles RecordSlide Number 40Slide Number 41Slide Number 42Slide Number 43Slide Number 44