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Lean Management Teachers Practice Proces Analysis Mini Kata More Often Ideas building on Mike Rothers work using recent experience with beginning practitioners. March 2012 Emiel van Est
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LeanManagement
Teachers
Practice Proces Analysis Mini Kata More Often
Ideas building on Mike Rothers work using recent experience with beginning
practitioners.
March 2012 Emiel van Est
Improvement Kata & Coaching Kata
We practice the Improvement Kata & Coaching Kata as outlined in Mike Rothers Book Toyota Kata and the companion Handbook
© Lean Management Teachers 2
We notice these tables have a lot in common. Can we standardize?
© Lean Management Teachers 3
Customer Demand and Line Pace
• Customer takt • Planned cycle time • Number of shifts currently running
Overview of the Process
• Define the start & end points of the process • Get to know the process by sketching a block diagram of it
- Where does WIP accumulate? • How much does process output fluctuate? (Cycle-to-cycle and shift-to-shift) • Note other details about the current operating pattern
Machine Capacity • Can the automatic equipment support the planned cycle time? • How close are we to our current machine capacity limit? • What is the fastest Pc/t the equipment can currently support? • Shift options?
Process Fluctuation
• Time 20-40 full cycles of each operatorʼs work • Are each operatorʼs work steps the same from cycle to cycle?
No Yes
No Yes
Necessary Number of Operators (if process were stable)
• Calculate number of operators
WHAT INFORMATION IS IN A TARGET CONDITION? A target condition describes how you want a process to operate
• A target condition for a manufacturing process should include the following four categories of information. • No verbs in a target condition. Thatʼs for how to get there. • You must include a target date for achieving the target condition.
Achieve-By Date: (required)
(1) DESCRIBE PROCESS STEPS, SEQUENCE & TIMES A pattern you can draw or chart (see example)
(2) OTHER PROCESS CHARACTERISTICS
Used for improving
Used to check
outcomes
Examples: • Number of operators • Number of shifts • Where 1x1 flow is planned, and where standard WIP
(incl. quantity) is to be located • Leveling sequence
(3) PROCESS METRIC(S) (Measurement in the moment)
For checking process condition in real time Examples: • Time for each step, piece, pitch, etc.
• Degree of time fluctuation from cycle to cycle
(4) OUTCOME METRIC(S) To check outcome of improvement efforts Examples: • Number of pieces per hour or shift
• Leveling sequence attainment • Productivity
© Improvement Kata Handbook Target Condition 11
Process: Challenge: TC date:Theme of this TC:
Step 1: Fill in current condition data Current
Condition Target
Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
This can be a generic format for the Process Analysis Mini Kata
© Lean Management Teachers 4
Customer Demand and Line Pace
Target Output per day (1)Number of shiftsTakt timePlanned Cycle TIme
Overview of the Process
See drawing for steps; sequence and timesNumber of operatorsWhere Work In ProcessWhere 1x1 flow
See run chart for output cycle fluctuation (2)
Machine Capacity
Can automatic equipment support the planned cycle time?
Process Fluctuation
See run chart for operator cycle fluctuationAre operators work steps the same form cycle to cycle?
Necessary Number of Operators if process were stable
Necessary Number of Operators
Customer Demand and Line Pace
Overview of the Process
Machine Capacity
Process Fluctuation
Necessary Number of Operators if process were stable
Manufacturing Processes Other Processes
We can use this Mini Kata in many phases
© Lean Management Teachers 5
Customer Demand and Line Pace
Overview of the Process
Machine Capacity
Process Fluctuation
Necessary Number of Operators if process were stable
Customer Demand and Line Pace
Overview of the Process
Machine Capacity
Process Fluctuation
Necessary Number of Operators if process were stable
Customer Demand and Line Pace
Overview of the Process
Machine Capacity
Process Fluctuation
Necessary Number of Operators if process were stable
Customer Demand and Line Pace
Overview of the Process
Machine Capacity
Process Fluctuation
Necessary Number of Operators if process were stable
Customer Demand and Line Pace
Overview of the Process
Machine Capacity
Process Fluctuation
Necessary Number of Operators if process were stable
Mini Kata in Target Condition FormManufacturing
© Lean Management Teachers 6
Process: Challenge: TC date:Theme of this TC:
Step 1: Fill in current condition data Current
Condition Target
Condition
Step 2: Fill in what you will keep
the same Step 3: Fill in what
you want to change
Process Metric (2):
Outcome Metric (1):
Customer Demand and Line Pace
Target Output per day (1)Number of shiftsTakt timePlanned Cycle TIme
Overview of the Process
See drawing for steps; sequence and timesNumber of operatorsWhere Work In ProcessWhere 1x1 flow
See run chart for output cycle fluctuation (2)
Machine Capacity
Can automatic equipment support the planned cycle time?
Process Fluctuation
See run chart for operator cycle fluctuationAre operators work steps the same form cycle to cycle?
Necessary Number of Operators if process were stable
Necessary Number of Operators
Customer Demand and Line Pace
Target Output per day (1)Number of shiftsTakt timePlanned Cycle TIme
Overview of the Process
See drawing for steps; sequence and timesNumber of operatorsWhere Work In ProcessWhere 1x1 flow
See run chart for output cycle fluctuation (2)
Machine Capacity
Can automatic equipment support the planned cycle time?
Process Fluctuation
See run chart for operator cycle fluctuationAre operators work steps the same form cycle to cycle?
Necessary Number of Operators if process were stable
Necessary Number of Operators
Process: Challenge: TC date:Theme of this TC:
Step 1: Fill in current condition data Current
Condition Target
Condition
Step 2: Fill in what you will keep
the same Step 3: Fill in what
you want to change
Mini Kata in Target Condition FormOther Processes
© Lean Management Teachers 7
Customer Demand and Line Pace
Overview of the Process
Machine Capacity
Process Fluctuation
Necessary Number of Operators if process were stable
Customer Demand and Line Pace
Overview of the Process
Machine Capacity
Process Fluctuation
Necessary Number of Operators if process were stable
Process Metric (2):
Outcome Metric (1):
So, we can practice this Mini Kata twice during every coaching cycle!
© Lean Management Teachers 8
Customer Demand and Line Pace
Overview of the Process
Machine Capacity
Process Fluctuation
Necessary Number of Operators if process were stable
Customer Demand and Line Pace
Overview of the Process
Machine Capacity
Process Fluctuation
Necessary Number of Operators if process were stable
LeanManagement
Teachers
What do you think?Is this an improvement?
Let me know!
© Lean Management Teachers 9
