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
Lean Frontiers, Inc. TWI Institute KataCon & TWI Summit Feb. 18-22, 2019www.leanfrontiers.com www.twi-institute.org www.leanfrontiers.com/skillsweek 2
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
Lean Frontiers, Inc. TWI Institute KataCon & TWI Summit Feb. 18-22, 2019www.leanfrontiers.com www.twi-institute.org www.leanfrontiers.com/skillsweek 3
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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2
3
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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
Get the Direction orChallenge
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2
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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
Lean Frontiers, Inc. TWI Institute KataCon & TWI Summit Feb. 18-22, 2019www.leanfrontiers.com www.twi-institute.org www.leanfrontiers.com/skillsweek 4
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
Lean Frontiers, Inc. TWI Institute KataCon & TWI Summit Feb. 18-22, 2019www.leanfrontiers.com www.twi-institute.org www.leanfrontiers.com/skillsweek 5
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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2
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Obstacles are the real problems you NEED to work on to move forward!
Get the Direction orChallenge
Obstacles
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 6
Case study, Current condition
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Target Condition: ”One side at a time”
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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 7
Obstacles came up!
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Layoutissues Toolsissues Fixtures
The destination…..
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