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

The 7 Kata
Toyota Kata, TWI, and Lean Training

ISBN 9781439880777
Published June 22, 2012 by Productivity Press
191 Pages 36 B/W Illustrations

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Book 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 explains why a mix of the skill sets that Training Within Industry (TWI) and the Toyota Kata (behavior patterns) teach is the ideal recipe to boost 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

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

The Coaching Kata: Teaching to Learn
Preceptor Development
Coaching Philosophy
Coaching and Improvement Kata Card Revision
Developing a Kata Culture Using a Training Timetable
     The JR Connection
     Coaching the Problem-Solving Kata

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

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
Foundations for Good Relations
JR Kata and A3 Thinking

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?

The Job Methods Kata: Kipling’s Kata
Relationship of the Improvement and JM Kata
Proposals and the Nascent Teian Program
JM Kata
     JM Analysis
     Nemawashi and A3 Thinking
     Continuous Improvement

Submit to the Kata
First Things First
Adaptive Learning

Appendix: A Lean Training Within Industry (TWI) Timeline

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