jim huntzinger dwayne - lean...

10/21/2014

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BE BOLD. BE BETTER.

1 www.leanfrontiers.com

Jim HuntzingerLean Frontiers,

President and Founder

Dwayne ButcherLean Frontiers,

Vice President

BE BOLD. BE BETTER.

TWI, Kata & Coachingin the Lean Enterprise:

the Foundations to Learning and Lean Integration


Jim Huntzinger & Dwayne ButcherOctober 21 & 22, 2014

10/21/2014

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BE BOLD. BE BETTER.

The Lean Enterprise

I N T E G R A T I O N

C


COACHING

KATA (IK/CK)

TWI

BE BOLD. BE BETTER.

TWI‐Coaching‐Kata

Integrating Learning into a Hands‐On & One‐on‐One approachas the Foundation to developing Skill and Knowledge for

Problem‐Solving based on the Scientific Method (PDCA) through direct application on actual operations and projects


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BE BOLD. BE BETTER.


Objective: Create an organization that solves bl t ti d t l lproblems at any time and at every level.


BE BOLD. BE BETTER.


How?: Develop problem solving skills and knowledge in every individual.


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How do you develop those skills and knowledge? Create coaching/mentoring relationship… Create coaching/mentoring relationship…

where learning is hands‐on and one‐on‐one…

using the scientific method (PDCA)…

applied directly to actual operations and projects.


BE BOLD. BE BETTER.

The Five Basic Needs of SupervisorsSupervisors

Knowledge unique to the Company and/or Industry that supervisors must know to do their job:


1. Knowledge of the work

2. Knowledge of responsibilities

Knowledge training is the responsibility of each company and is not the focus of TWI

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BE BOLD. BE BETTER.

The Five Basic Needs of Supervisorsp

Skills required for supervisors to perform within their role, regardless of the industry:


3. Skill in Leading

4. Skill in Instruction

5. Skill in Methods Improvement

BE BOLD. BE BETTER.

The “J” ProgramsJob Relations (JR)

• Create a good working environment by resolving problems early• Dealing with abnormalities of people’s behavior at the worksite• Dealing with abnormalities of people s behavior at the worksite

Job Instruction (JI)• Prepare work standards and…• Provide training to ensure operators do their work according to

standards

Job Methods (JM)• Improve status quo by improving standards• Notice abnormalities and address immediately to keep the process

d l


under control

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BE BOLD. BE BETTER.

Learning from a Hands‐On & One‐on‐One approachas the Foundation to developing Skill and

K l d f P bl S l i b d th

You will not become lean by doing TWI, but

you will not become lean without doing TWI.

Knowledge for Problem‐Solving based on the Scientific Method (PDCA) through direct application


you will not become lean without doing TWI.

BE BOLD. BE BETTER.

TWI History: The 4‐Step Method

Steps Johann HerbartCharles Allen

TWI PDCA (Shewart/Deming

Cycle)

Scientific MethodJob

InstructionJob

MethodsJob

Relations

1 Prepare the pupils to be ready for the new lesson

PreparationPrepare the Worker

Breakdown the Job

Get the Facts

Plan – observe data and reality; decide on a

problem; define it

Observation and Description

2 Present the new lesson PresentationPresent the Operation

Question Every Detail

Weigh and Decide

Do – Analyze the problem; propose a countermeasure

Formulation of an Hypothesis

3 Associate the new lesson with ideas studied earlier

ApplicationTry Out

PerformanceDevelop New

MethodTake Action

Check – Try the countermeasure; check the results

Use the Hypothesis to make

Predictions


check the results Predictions

4 Use examples to illustrate the lesson’s major points

Testing (or Inspection)

Follow UpApply New Method

Check Results

Act – if successful, standardize change; if not, start the cycle

over

Test the Predictions by Experiments

5 Test pupils to ensure they had learned the new lesson

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BE BOLD. BE BETTER.

Plan

CurrentCondition

Target Condition

Unclear Territory

Learn By Doing

Do

Check

Act


Learn By Doing

Adapted from Mike Rother, 2009, Toyota Kata

BE BOLD. BE BETTER.

Improvement Kata (IK) & Coaching Kata (CK) Definitions

The Improvement Kata (IK) is a set of practice routines for learning to work scientifically when you pursue goals in a complex system.

The Improvement Kata (IK) is a teachable four‐step model of the scientific way of thinking and acting.

The Coaching Kata (CK) is a practice routine for teaching the Improvement K t tt


Kata pattern.

The Coaching Kata (CK) is a pattern for teaching the Improvement Kata.

Mike Rother, 2014, (http://www.slideshare.net/mike734/kata‐slides‐graphics)

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BE BOLD. BE BETTER.

THE FOUR STEPS OF THE O O

12 34

IMPROVEMENT KATA MODELA systematic, scientific pattern of working


VisionTargetCondition

CurrentCondition Obstacles Challenge

By Mike Rother

BE BOLD. BE BETTER.

CONNECTING STRATEGY AND EXECUTION

Leaders establish the organiza onʼs strategic concept (the “rallying point” or overall direction)

Managers develop people by coaching application practice of the Improvement Kata in the direction of the challenge


VisionTargetCondition

CurrentCondition Obstacles Challenge

By Mike Rother

Execution Strategy

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BE BOLD. BE BETTER.

“Back of a Napkin”


BE BOLD. BE BETTER.

Plan

CurrentCondition

Target Condition

Unclear Territory

Learn By Doing

Do

Check

Act


“trust the process”Learn By Doing

Adapted from Mike Rother, 2009, Toyota Kata

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BE BOLD. BE BETTER.

Teaching and mentoring thru questioning (TWI, Kata &Coaching) creates the behavior which mitigates and/org) g /eliminates problems. In applying/practicing TWI, massivefundamental learning takes place which changes thinkingwhich strengthens vision and understanding whichcreates acceleration and depth of knowledge.


“There is no substitute for knowledge.”W. Edwards Deming

BE BOLD. BE BETTER.

Building & Maturing the Lean CultureBy two levels of proficiency:

• Problem‐Solving and…• Problem‐Solving Coaching


…though Learning & Knowledge

Note: Thanks Karen,

10/21/2014

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BE BOLD. BE BETTER.

Thank You!Thank You!Lean Frontiers10609 N. Park Ave

Indianapolis, IN 46280

USA


Jim Huntzinger

[email protected]

www.leanfrontiers.com

Dwayne Butcher

[email protected]

www.leanfrontiers.com

jim huntzinger dwayne - lean...

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