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© Mike Rother TOYOTA KATA 1
Toyota KataMobilizing our ingenuity through good management
Mike Rother, February 2010
The practice of kata is the actof practicing a pattern so it becomes second nature.
In its day-to-day management Toyota teaches a way of working -- a kata -- that has helped make it so successful over the last six decades.
Toyotaʼs Improvement Katais something we overlook in benchmarking and shouldlearn more about in order to understand Toyotaʼs story.
Copyright © 2010 Mike Rother, all rights reserved1217 Baldwin Avenue / Ann Arbor, MI 48104 USA / tel: (734) 665-5411 / [email protected]
© Mike Rother TOYOTA KATA 2
An organizationʼs processes, practices and results are an outcome of peopleʼs thinking and behavior.
If processes are an outcome, then itʼs important to ask, How do we influence our behavior in order to accomplish continuous improvement, adaptiveness, and innovation?
Toyotaʼs answer is through kata. Kata are practice routines, like dance steps, that develop particular skills and ways of thinking.
© Mike Rother TOYOTA KATA 3
THE TOYOTA KATA DEFINITION OF MANAGEMENT
The systematic pursuit of desired conditionsby utilizing human capabilities
in a concerted way
We want to behere
We are here
Currentcondition
Desiredcondition
TargetconditionChallenge
© Mike Rother TOYOTA KATA 4
A MANAGEMENT TASKThe task is not to introduce new techniques, principles, ethics or solutions, but to establish a culture of continuous improvement, adaptation and innovation by practicing a method or behavior pattern that develops improvement skills and habits.
This is very much like training in sports.
© Mike Rother TOYOTA KATA 5
But leading people to implementing solutions doesnʼt make an organization adaptive and continuously improving. Hereʼs why:
• It caters to and strengthens our aversion to uncertainty,rather then developing exploratory mindset and skills
• Todayʼs solutions arenʼt the ones that will meet tomorrow's challenges
It's not solutions themselves that provide sustained competitive advantage. Itʼs the ability of the organizationʼs members to develop solutions.
HOW HAVE WE BEEN MANAGING?Leaders and managers have tended to focus on outcomes and solutions
A solution at Toyota... ...copied at a U.S. company
© Mike Rother TOYOTA KATA 6
(1) Where we are(2) Where we want to be(3) By what means we should navigate the
unclear territory between here and there.
We want to behere
We are here
Unclear Territory
This is a grey zone!
Obstacles
DEVELOPING SOLUTIONSThere are only 3 things we can and need to know with certainty
We donʼt know in advance what all the steps will be
© Mike Rother TOYOTA KATA 7
HOW DO YOU IMPROVE, ADAPT & INNOVATE?• How will you make your kanban system work?• How will you achieve 1x1 flow?• How will you achieve shorter value-stream lead time?• How will you achieve your objective?
The way forward is iterative & experimenting, aimed at a desired condition that we donʼt yet know how we will achieve.
Uncertainty / Learning Zone
NextTarget
Condition
Current KnowledgeThreshold
We wantto be here
next
Obstacles
Unclear
Territory
? ?
?
© Mike Rother TOYOTA KATA 8
BUT THERE IS A DILEMMA(A) Our brain favors existing neural pathways (comfort area)
The way our brain works we seek certainty and try to avoid judgement and criticism. We prefer to operate inside our current knowledge threshold.
(B) Meeting challenges - improving and adapting - means developing new neural pathways (learning area)
Itʼs impossible to remove uncertainty from the processof improvement, adaptation and creation. The way forward lies outside our current knowledge threshold.
Comfortarea
ApparentCertainty
Mystery
Uncertainty
Learningarea
© Mike Rother TOYOTA KATA 9
The trick is to develop well-worn mental circuits not for solutions, but for a means by which we deal with dynamic, uncertain conditions.
Like training in sports: To prepare for contests with unpredictable paths, the focus of the training is not solutions, but practicing how to play.
A SOLUTION TO THIS DILEMMA
People can handle uncertainty, work iteratively, adapt and meet challenges...
...if they have practiced and learned a way of doing that.
This concept is the basis of the book Toyota Kata
© Mike Rother TOYOTA KATA 10
The Toyota Kata Message:WE CAN MEET THE CHALLENGES FACING US
If we practice and learn an effective wayof navigating the learning zone
© Mike Rother TOYOTA KATA 11
Establish the Next Target Condition
TargetCondition
PDCA Toward the Target Condition
The 5 Questions
GoandSee
PLAN
CHECK DO
ACT
C C
T C
Grasp the Current
Condition
Understandthe
Direction
What challenge are we striving to meet?
The step-by-step discovery process between where we are and where we want to be next.
What pattern do we want to have next?
What is the current pattern of working?
321 4
THE PATTERN THAT TOYOTA PRACTICES:- THE IMPROVEMENT KATA -
The Improvement Kata is a four-part routine. Itʼs a systematicand scientific way for people to successfully navigate
through unknown territory together.Itʼs the backbone practice in a Lean organization.
© Mike Rother TOYOTA KATA 12
Fractal depiction by Mr. Emiel van Est
THE IMPROVEMENT KATA IS FRACTALBecause the Improvement Kata is content neutral
it can be practiced throughout an organization
Itʼs a decentralized yet aligned process of improvement, adaptation and innovation
© Mike Rother TOYOTA KATA 13
AND THEREʼS A COACHING KATAFOR TEACHING THE IMPROVEMENT KATA
The Coaching Kata is a set of coaching routines to practice in order to develop effective coaching habits. It's a coaching pattern to help you teach the Improvement Kata thinking pattern.
The Coaching Kata gives managers and supervisors a standardized approach to facilitate Improvement Kata skill development in daily work.
The coach needs to know both the Improvement Kata and the Coaching Kata!
© Mike Rother TOYOTA KATA 14
HOW DO YOU CHANGE MINDSETAND ORGANIZATION CULTURE?
From one of implementing pre-defined solutions,to one of actively developing new solutions
Psychology and brain research are clear:Humans have the ability to alter their mindset. Our brain is equipped for learning new rules, patterns and habits.
© Mike Rother TOYOTA KATA 15
Dendrites (receiver)Cell
BodyAxon (sender)
The human brain is estimated to contain 100 billion neurons. Neurons form circuits within the brain, which underlie perception and thought.For communication between two neurons to take place, an electrical impulse travels down an axon to a synapse, or gap, where transmission occurs.Both the strength of connection between neurons (ease of information transmission) and the number of connections increase with use. Whatever you focus on and practice - with associated emotions - weaves a habit or pattern into your thinking. (Emotion helps determine what to imprint.)
MINDSET = NEURAL PATHWAYS OR CIRCUITSItʼs physiological
“Every time you do something,you are more likely to do it again.”
~ Alvaro Pascual-Leone
© Mike Rother TOYOTA KATA 16
TO CHANGE MINDSET AND DEVELOP NEW SKILLS FOCUS ON THESE ELEMENTS
PRACTICERepetition
COACHINGCorrective feedback
KATAStructured routine
to practice
MASTERYOvercoming
obstacles
To develop new habits through practice, aLearner will have to experience success.It will be the responsibility of the Coach to give the Learner procedural guidance that makes the Learner successful in overcoming obstacles on the way to their target condition.
© Mike Rother TOYOTA KATA 17
THIS LEADS TO A NEW CONSIDERATIONFOR LEADERSHIP AND MANAGEMENT
In order to practice you need to know what to practiceTo change mindset and culture through deliberate practice, the organizationʼs leaders should specifythe pattern that is to be practiced and coached.The organizationʼs managers should learn the pattern and how to coach it.Thatʼs exactly what Toyota does... Toyotaʼs managers teach a common means for developing solutions: The Improvement Kata.
Solution How todevelop solution
OurManagement
SystemGiven / Directed
ToyotaʼsManagement
SystemSpecified
Guided & directedLeft open
Left open
© Mike Rother TOYOTA KATA 18
MAKE THE PRACTICING PART OF NORMALDAILY WORK, NOT A SPECIAL EVENT
If we only periodically conduct training events or only episodically work on improvement -- and the rest of the time itʼs business as usual -- then according to neuroscience what weʼre actually teaching is business as usual.
If we want a Lean revolution, then we need to shift emphasis from staff-led, episodic improvement efforts, to daily efforts led by middle managers.
A slice of each day should be focused on iterating toward the next target condition by applying & coaching the Improvement Kata.
Supervisor
AreaManager
Daily
© Mike Rother TOYOTA KATA 19
ONE CONCLUSION IS BECOMING CLEARWeʼre not going to be successful by copying Toyotaʼs solutions
We should be copying how Toyota develops solutions.(Which is a universal, not Toyota-specific, science-based approach.)
The Improvement Kata and Coaching Kata are practice routines for teaching and transferring that approach.
Once you develop proficiency with the Improvement Kata and Coaching Kata you can evolve them into kata that suit your organization.
© Mike Rother TOYOTA KATA 20
NextTarget ConditionTarget
Condition
CurrentCondition
Illustration by Dr. Lutz Engel
The more people in an organizationwho get to higher skill levels with the Improvement Kata pattern:• The more challenges the organization
can take on• The bigger the challenges it can take on• The more knowledge it can build• The faster it can move ahead
INCREASING YOUR ORGANIZATIONʼS CAPABILITYPracticing the Improvement Kata = expanding peopleʼs comfort zone
ApparentCertainty
Mystery
Uncertainty
Comfortarea
© Mike Rother TOYOTA KATA 21
We confused the visible content of what we benchmarked at Toyota withthe less visible method Toyota uses to pursue objectives.
We called what we observed Lean, which suggests always minimizing or maximizing. This idea easily fits into our existing thinking in business, making it harder for us to see the different management approach Toyota is taking.
As I see it now, Toyotaʼs extraordinary successes came from Lean practices combined with Toyotaʼs way of working toward any challenging objective. Toyotaʼs improvement kata is about solving problems and adapting as you strive to move from where you are to where you want to be next. That can involve minimizing, optimizing, or whatever you wish to achieve.
WE MISUNDERSTOOD THE SOURCEOF TOYOTAʼS SUCCESSES
• Solve a problem• Lean practices• Develop a product• Market a product / service• etc.
This is content and situation specific
How we go about it TheImprovement Kata
This is content free and universal
What we work on
The pivotal change proposed by study of Toyota is not in whatan organization does, but in how the organization does it
© Mike Rother TOYOTA KATA 22
WHAT IS MANAGEMENTʼS TASK?
TraditionalManagement
Toyota KataManagement
• Establish targets
• Describe solutions
• Provide incentives
• Get out of the way and periodically check results
• Establish targets
• Develop, via practice with coaching, the capability in people to develop new solutions......by having people practice a common way of working, like the Improvement Kata
Focus on solutions Focus on howsolutions are developed
© Mike Rother TOYOTA KATA 23
MANAGERS ARE TEACHERS, ANDTHEIR ACTIONS DETERMINE COMPANY CAPABILITY
Whether consciously or not, with their everyday words and actions all managers are teaching their people a mindset and approach.
So it makes sense to ask: “What patterns of behavior and thought do we want to be teaching in our organization?”
© Mike Rother TOYOTA KATA 24
How do we make a transition from our prevailing management approach, to systems thinking?
We change by practicing a different behavior. That, over time, leads us to think about things differently.
What pattern of acting and thinking-- what teachable, transferrable routine -- can we practice?
With the Improvement Kata and Coaching Kata we have routinesthat can be applied and practicedin any setting, in order to develop capability and behavior consistent with systems thinking.
résumé
© Mike Rother TOYOTA KATA 25
The Toyota Kata Website
FURTHER RESOURCESClick each item or scan the code for a link to that resource
Essential Books
© Mike Rother TOYOTA KATA 26
Toyota Kata on
Improvement Kata Handbook(Download free on the Toyota Kata Website)
TK Course at UM