Toyota Kata (PDFDrive) PDF
Toyota Kata (PDFDrive) PDF
Toyota Kata (PDFDrive) PDF
Witecy 2012). Liker (2012) and Rother (2009) name the way to LM as the
cause for this underperformance. Western companies mostly approach the
lean philosophy by setting up projects, who apply lean methods like value
stream mapping and kanban to smooth the processes and thereby improve
the process flow. This results in a significant process improvement first; but
after the project end, the process will not be further improved and stay, in
the best case, at the created level.
Toyota follows a different approach, whereby employees on the shop floor-
level are entrusted with the task of process improvement. Their goal: a con-
sistent and target-oriented development of new standards in the processes
of value creation. This strongly emphasis a mixture of soft factors like lead-
ership skills for empowering the employees and hard factors like methods
to analyze the processes.
Liker (2007) underlines this hypothesis by referencing to an internal Toyota
Document, which describes the fundamental Toyota Principles guiding the
way to a LM Implementation, named the 4P-Model (Figure 1). Thereby, the
fundament is laid by a philosophy, achieving a long-term vision, which in
the Toyota case is a just in time process (Rother 2009). The second layer is
a guide for process development following certain principles, i.e. leverag-
ing the customer needs and creating flow, to approach the vision. The third
and fourth layer emphasize the importance of soft factors, like the way of
collaboration between employee and supervisor, as a basis for process im-
provement at the shop floor-level, which has been neglected in western LM
approaches so far.
178 Matthias Ehni and Wolfgang Kersten
Problem
Solving
(CI and
Learning Processes)
People / Partner
(respect, challenged promote)
Process
(Elimination of waste)
Philosophy
(Long-term thinking)
Aiming to fill the research gap, Liker and Franz (2011) as well as Rother
(2009) focused their research on the questions how the improvement pro-
cesses of Toyota are structured and how they could be integrated into the
behavioral routines at the shop floor level. Liker and Franz (2011) identified
the Toyota Business Practices (TBP) as the method used for continuous im-
provement (CI) at the shop floor level. The TBP are inspired by a simple
PDCA cycle and follow 8 steps:
1. Define the problem in relation to the ideal state (Plan),
2. Capture the current state (Plan),
3. Identify the root cause (Plan),
4. Set an improvement target (Plan).
5. Select a suitable approach (Plan),
6. Experiment (Do),
7. Control the results (Check),
8. Adapt, standardize and spread the solution (Act).
Toyota Kata 179
Occur
Problems Next
Current target
and Vision
state condition
barriers
Understand
and overcome
The basic idea is the strategic orientation on a long-term target (step 1). In
case of Toyota this is a Just-In-Time-Principle representing a process with
no waste, which provides an orientation for the improvement activities.
Step 2 is about understanding the current situation of the process in scope.
Depending on the current situation, a reachable, short term target in direc-
tion towards the long-term target can be defined (Step 3). Step 4 is a step
by step approach to reach the set target. For the step by step approach ex-
periments are applied. Within these experiments a hypothesis is formu-
lated first. Second, experiments are performed within the process. Third,
result and hypothesis are compared. Fourth, if the hypothesis can be con-
firmed the experiment is standardized and implemented into the process.
The Coaching Kata on the other hand is the complementary routine to the
Improvement Kata. It serves in providing the needed skillset for the im-
prover, guiding him with questions by a coach through the improvement
process (Figure 3).
Toyota Kata 181
Improvement Kata
1. Understand Reflection
Vision
2. Understand 3. Define 4. A P
Current State target cond. C D
2 Research Methodology
The project aims at answering the research questions, which include sub-
jective and interpretative parts as they deal with behavioral aspects
(Frankel, Naslund, und Bolumole 2005). For obtaining scientific results in
this area qualitative methods are particularly suitable (von Rosenstiel 2005,
238).
To meet this demand the research project follows a methodology sug-
gested by Gläser and Laudel (2010). It is based on three steps,
1. Preparation of the empirical research,
2. Conducting the empirical research,
3. Analysis of the data, which are used to structure this section.
Management Philosophy
Normative Management
Corporate Policy
Corporate Corporate
Constitution Missions Culture
VERTICAL INTEGRATION
Strategic Management
Operative Management
Organizational Cooperative
Tasks
Processes Behavior
Corporate Development
Into this generic approach the theory of lean management was embedded,
filling every pillar from the normative to the operational management per-
spective. As a result a complete theoretical picture on implementing LM
considering culture change through the different management perspec-
tives was developed and used for the deduction of an interview guideline,
confirming that important aspects were included.
Toyota Kata 185
B 1 No No Yes
Consul-
5 Yes Yes Yes
tancy
Causal Mechanism of
class of cases
3 Results / Findings
In this section the results of the case studies as well as the derived concept
developed by the analysis of the cases are presented. The section will be
structured, regarding to the research questions, in three sections. In the
first section fundamental elements of the CI process as well as the process
itself are described. The second section is presenting the derived imple-
mentation approach for the CI process. In the third and last section the
evaluation approach for measuring the success of the concept is intro-
duced.
3.1 Method of CI
Both companies as well as the consultancy applied a CI method which is
very similar to the approach by Rother (2009). They used the Improvement
as well as the Coaching Kata. Nevertheless, they added additional elements
like roles, detailed procedures for process analysis and a procedure to
transform the vision into individual improvement targets.
Toyota Kata 189
In a last step the challenge, which was on plant-level, was derived into tar-
gets for the different departments.
After the workshop the department managers conducted target agreement
discussions with their employees. Input for the discussion was the target
agreement of the department manager. His target agreement was then
transferred into suitable targets for the employee applying the method of
"catchballing". Thereby, the department manager asked the employee to
check the target for feasibility. After a plausibility check the targets were
either accepted or renegotiated. The process was repeated through all hi-
erarchy levels to the level of the improver. This procedure, cascading the
vision to the operational level, ensures that all operational improvement
activities add to the big picture and thereby enhance the companies' tar-
gets (figure 6).
Phase 1:
Vision Workshop Vision
Challenge
Target Target
Department 1 Department 2
The coach acted very closely to the questions suggested by Rother, which
is very helpful to guide the improver through the process. The consultancy
pointed out, that a very important step is the definition of the target condi-
tion. It should be placed in a so-called learning zone, where the target is
challenging but not out of reach. Thereby, the improver does not get frus-
trated but motivated.
The companies were very strict on not providing decisions by the coach.
Even if the improver had a suggestion, which obviously did not point in the
right direction, the coach just led through questions. If the learner did not
see the point, he did an experiment and gained experience.
Nevertheless, the two companies decided to add the role of a 2nd coach.
The 2nd coach provides a feedback to coach on a regular basis and thereby
develops the coaching skills. Coaching as well as the feedback through the
Toyota Kata 193
2nd coach were held on a regular basis. In the observed companies coach-
ing took place once a week. The feedback from the 2nd coach was provided
one to two times a month.
After the management-buy-in the setting for the project was designed in
cooperation with the consultancy. Therefore, the scope of the project re-
garding the companies' penetration as well as personnel and financial re-
sources was set. Both companies started with a pilot area. Within the pilot
area the total numbers of improvers, coaches and 2nd coaches were
named. In the observed cases the role assignment was strictly oriented on
hierarchy. The improvers were the team-leaders of the departments in
scope. The next hierarchy level was entrusted with the task of the coaches,
while the 2nd coach was either a lean expert or the department manager.
The consultancy emphasized that a role allocation due to hierarchy is a rea-
sonable approach, but is not mandatory. Other possibilities might be the
integration of staff positions etc.
194 Matthias Ehni and Wolfgang Kersten
While one company just focused on the shop floor-level as the area of im-
provement, the other company wanted to implement the improvement
routine through all hierarchy levels. A restructuring of the organization
was in neither company in scope. The reason for this exclusion is an ap-
proach, which prefers "function before structure". On the one hand the
companies stated that workflow-oriented structures might be helpful for
reducing potential losses in interfaces between the departments. But on
the other they wanted to focus on the change in the improvement culture.
This is best achieved with trusted work relationship and thereby sticking
to the old structures.
For the role out, initial training was provided. Thereby, in phase 1 the top
hierarchy level underwent an in-depth Improvement kata training under
guidance of the consultancy. When the routine was internalized phase 2 be-
gun. In phase 2 the top hierarchy level managers took the role of the
coaches and trained the next hierarchy level in the Improvement kata.
Within that training the top managers were supervised by the consultancy,
taking the role of the 2nd coaches. In the next phases this procedure was
repeated till the learners on operational level were trained. This top-down
training approach, which follows best practices in learning, as you learn in
small steps with a trusted coach in a working environment, is visualized in
figure 7.
Toyota Kata 195
A P A P A P
C D C D C D
improvement efforts, which were tracked in the cost standards, were offset
against.
In calculations of both companies benefits outweighed the costs. While one
company didn’t name exact numbers, the other had a positive result better
than 0.5 Mio € in 2013 and a total sum close to 1.8 Mio € within 4 years after
the start.
3a. Actions
Vision
Workshop 5.
and Target 4. Applying
1. 2. Monetary
Cascading the Kata at
Leadership Setting the and Non-
Shop-
Buy-In Scope 3b. Monetary
Floor-Level
Top-Down- Evaluation
Training of
Staff
Figure 8 Summary of the LM Implementation Approach
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