The 7 Kata: Toyota Kata, TWI, and Lean Training, 1st Edition (Paperback) book cover

The 7 Kata

Toyota Kata, TWI, and Lean Training, 1st Edition

By Conrad Soltero, Patrice Boutier

Productivity Press

191 pages | 36 B/W Illus.

Shingo Award Winner
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Description

The biggest competitive advantage an organization can achieve comes from the synergies created by employees skilled in enhancing organizational dynamics. The Seven Kata: Toyota Kata, TWI, and Lean Training supplies time-tested tools and advice to help readers adapt to changing conditions and outcompete their rivals. It explainswhy a mix of the skill sets that Training Within Industry (TWI) and the Toyota Kata (behavior patterns)teachis the ideal recipe toboost organizational synergies and enhance any Lean transformation.

Winner of a 2013 Shingo Prize for Operational Excellence!

Bridging the kata/TWI nexus, the book lays out a road map for Lean success. It devotes a chapter to each of the Seven Kata and suggests possible courses of action dependent on your organization’s strengths and constraints. Bringing together valuable information on many of the disjointed Lean practices, it explains key Lean concepts, including gemba walks, genchi gembutsu, and PDCA.

After introducing kata, it reveals the different kata inherent in the three major TWI courses and the TWI Job Safety course. It illustrates the value stream analysis relationship to the kata and the kata relationship to TWI. It also demonstrates how to use kata to solve the problems identified in your value stream analysis while simultaneously conditioning your employees’ adaptive thinking patterns.

Supplying a clear understanding of exactly where the seven kata apply in your Lean journey, the authors include helpful guidelines for coaching a kata. They also highlight mistakes they have experienced or witnessed so you can avoid the same pitfalls. As globalism continues to make management’s organizational skills a competitive differentiator, this book provides you with the tools to use the seven kata to place your organization on a discernible path towards operational excellence.

Listen to what Pat Boutier has to say about The Seven Kata.

Part One Part Two

Table of Contents

Weapons for the Economic Warrior

Skills, Not Tools

Toyota’s Connective Tissue

Skills of the Warrior

Training Within Industry’s Japanese Connection

Lean’s Formula: Syncretism and Ritual

Getting Started

A Word of Warning to Top Management

The Improvement Kata: Kaizen

Means to an End—Kata and Kaizen

Value Stream Analysis

Improvement Kata Method

Coaching the Improvement Kata

The Five Questions

Yokoten

Conclusions

The Nested Job Instruction Kata: Learn to Teach

Training to Instruct

On-the-Job Training Development

Power of One-on-One

Quintessential Standard—Demonstrated

Nested Kata

Important Step (IS) Kata

Key Point (KP) Kata

The Kata for How to Get Ready to Instruct

From Training Course to Kata

Conclusions

The Coaching Kata: Teaching to Learn

Introduction

Preceptor Development

Coaching Philosophy

Coaching

Coaching and Improvement Kata Card Revision

Developing a Kata Culture Using a Training Timetable

The JR Connection

Coaching the Problem-Solving Kata

Conclusion

The Problem-Solving Kata: Seek to Understand Kata

Unconsciously Neglecting Problems

PS Kata

PS Kata Family

Training Within Industry Problem-Solving Training

Six Sigma in Context

Conclusions

The Job Relations Kata: The Cultural Fortifier

Collaboration and Conciliation

Practicing the JR Kata

Need for Coaching

Coaching the JR Kata

Practicing the JR Kata

Step 1

Step 2

Step 3

Step 4

Reflection

Foundations for Good Relations

JR Kata and A3 Thinking

Conclusion

Job Safety Kata: The Duplex Kata

JS Improvement Kata

JS Improvement Kata: Step 1

JS Improvement Kata: Observations

JS Problem-Solving Kata

JS Problem-Solving Kata: Step 2

JS Problem-Solving Kata: Step 3

JS Problem-Solving Kata: Step 4

JI Kata Connection

A New 5-Why?

Conclusions

The Job Methods Kata: Kipling’s Kata

Introduction

Relationship of the Improvement and JM Kata

Coaching

Proposals and the Nascent Teian Program

JM Kata

JM Analysis

Nemawashi and A3 Thinking

Continuous Improvement

Conclusion

Submit to the Kata

First Things First

Adaptive Learning

Conclusion

Biographies

References

Appendix: A Lean Training Within Industry (TWI) Timeline

About the Authors

Conrad Soltero and Patrice Boutier are with the TMAC in El Paso, Texas.

Subject Categories

BISAC Subject Codes/Headings:
BUS053000
BUSINESS & ECONOMICS / Quality Control
BUS070050
BUSINESS & ECONOMICS / Industries / Manufacturing Industries
BUS097000
BUSINESS & ECONOMICS / Workplace Culture