SFM Kata Connection
MLC conference
2014
W3 Business Systems
W3 Group, LLC
Roles & Responsibilities
Team Member





Perform work to current standard
Maintain 5-S in their work area
Perform routine minor maintenance
Look for Continuous Improvement
opportunities
Support Problem Solving small group
activities
Team Leader
• Process start-up and control
• Meet production goals
• Respond to TL calls by TM
• Confirm quality - routine checks
• Cover absenteeism
• Training and cross-training
• Work orders for quick maintenance
• Insure Standardized Work is followed
• Facilitate small group activities
• On-going Continuous Improvement
projects
• Insure parts / materials are supplied to
process
W3 Business Systems
Group Leader
• Manpower / vacation scheduling
• Monthly production planning
• Administrative: policy, attendance,
corrective actions
• Team morale
• Confirm routine quality and TL checks
• Shift to shift coordination
• Process trials
• TM development and cross-training
• Report / track daily production results
• Cost reduction activities
• Process improvement projects :
productivity, quality, ergonomics, etc.
• Coordinate major maintenance
• Coordinate support from outside groups
• Coordinate work with up-stream and
down-stream processes
• Group safety performance
• Help cover TL absence
• Coordinate activities around major
model changes
W3 Group, LLC
Kata Connection
Minicompanies
Glass walls
Ownership at
the process
Lean Tools
Standard work
Etc…
Shop Floor
Management
Policy
Deployment
Continuous
Improvement
W3 Business Systems
Hoshin Kanri
Management by
Planning
Annual Goals &
Objectives
Organizational
engagement &
alignment
A3 Problem
Solving
Six Sigma
Value Stream
Maps
Toyota Kata
W3 Group, LLC
W3 Business Systems
W3 Group, LLC
SFM Structure/Alignment
PARTICIPANTS
Operator
External
Coach
W3 Business Systems
Team
Leader
Group
Leader
Manager
The degree of involvement of the coach is dependent on
the SFM’s degree of maturity. While being a frequent
observer in the beginning, the coach will slowly reduce
the amount of involvement.
W3 Group, LLC
Traditional Organization
Plant Manager
DIRECTIVE
General Supervisor
Supervisor
Value-Add
Operator
W3 Business Systems
W3 Group, LLC
Future State Organization
Team
Members
SUPPORTIVE
Team
Leader
Group
Leader
Manager
BPS
W3 Business Systems
Maint
Pur
PC
ME
Trans
Quality
Whse
W3 Group, LLC
SFM Structure/Alignment
TEAM LEVEL
Monthly
Weekly
?
!
!
!
Monthly
SFM Routine
Reflection & Feedback
Reflection & Feedback
Daily
Weekly
Monthly
W3 Business Systems
W3 Group, LLC
Daily SFM Coaching Routine
5. Delivery
1. Safety
last 24h / next 24h
Where are we in relation to
the goal? (KPI)
Use questions to inquire
about the problem
(examples)
last 24h / next 24h
Go and See as much as
you can.
Problem
4. Cost
last 24h / next 24h
Where are we in relation to
the goal? (KPI)
Did we understand the problem?
Can you explain the problem?
Do we need to go & see to fully
understand?
What can we do immediately?
Do you see any benefit in writing
this down?
What can I do to help?
How can I help?
2. Attendance
last 24h / next 24h
How much capacity do we need and
have?
Are people working where we need
them?
If you encounter:
= No issue, move on to next point of the
routine
= Move to the problem section , investigate
W3 Business Systems
3. Quality
last 24h / next 24h
Where are we in relation to
the goal? (KPI)
REV 2.2
W3 Group, LLC
SFM Structure/Alignment
DEPARTMENT UNIT LEVEL
?
!
!
!
Monthly
SFM Routine
Reflection & Feedback
Daily
Monthly
W3 Business Systems
Reflection & Feedback
W3 Group, LLC
Daily SFM Coaching Routine
5. Delivery
1. Safety
last 24h / next 24h
Where are we in relation to
the goal? (KPI)
Use questions to inquire
about the problem
(examples)
last 24h / next 24h
Go and See as much as
you can.
Problem
4. Cost
last 24h / next 24h
Where are we in relation to
the goal? (KPI)
Did we understand the problem?
Can you explain the problem?
Do we need to go & see to fully
understand?
What can we do immediately?
Do you see any benefit in writing
this down?
What can I do to help?
How can I help?
2. Attendance
last 24h / next 24h
How much capacity do we need and
have?
Are people working where we need
them?
If you encounter:
= No issue, move on to next point of the
routine
= Move to the problem section , investigate
W3 Business Systems
3. Quality
last 24h / next 24h
Where are we in relation to
the goal? (KPI)
REV 2.2
W3 Group, LLC
SFM Structure/Alignment
PLANT LEVEL
?
!
!
!
Monthly
W3 Business Systems
SFM Routine
Reflection & Feedback
Daily
Monthly
W3 Group, LLC
Daily SFM Coaching Routine
5. Delivery
1. Safety
last 24h / next 24h
Where are we in relation to
the goal? (KPI)
Use questions to inquire
about the problem
(examples)
last 24h / next 24h
Go and See as much as
you can.
Problem
4. Cost
last 24h / next 24h
Where are we in relation to
the goal? (KPI)
Did we understand the problem?
Can you explain the problem?
Do we need to go & see to fully
understand?
What can we do immediately?
Do you see any benefit in writing
this down?
What can I do to help?
How can I help?
2. Attendance
last 24h / next 24h
How much capacity do we need and
have?
Are people working where we need
them?
If you encounter:
= No issue, move on to next point of the
routine
= Move to the problem section , investigate
W3 Business Systems
3. Quality
last 24h / next 24h
Where are we in relation to
the goal? (KPI)
REV 2.2
W3 Group, LLC
SFM Routine
TEAM LEVEL
Learning and
reflection through
observation
?
!
!
Learning and
reflection through
observation
!
SFM Routine
Reflection & Feedback
1. Inquire Status
4.(Go&See)
W3 Business Systems
2. Answer
3. Documentation
W3 Group, LLC
Daily SFM Coaching Routine
5. Delivery
1. Safety
last 24h / next 24h
Where are we in relation to
the goal? (KPI)
Use questions to inquire
about the problem
(examples)
last 24h / next 24h
Go and See as much as
you can.
Problem
4. Cost
last 24h / next 24h
Where are we in relation to
the goal? (KPI)
Did we understand the problem?
Can you explain the problem?
Do we need to go & see to fully
understand?
What can we do immediately?
Do you see any benefit in writing
this down?
What can I do to help?
How can I help?
2. Attendance
last 24h / next 24h
How much capacity do we need and
have?
Are people working where we need
them?
If you encounter:
= No issue, move on to next point of the
routine
= Move to the problem section , investigate
W3 Business Systems
3. Quality
last 24h / next 24h
Where are we in relation to
the goal? (KPI)
REV 2.2
W3 Group, LLC
Phases During the SFM Coaching Routine
What can
we expect
to see
tomorrow?
!
?
Learning through
observation and self
reflection
Learning through
practicing the routine
1. SFM Coaching Routine
3. Summary and Expectation
This was
my
impression
….
2. Clarification / feedback round
W3 Business Systems
Learning through
feedback and self
reflection
4. Feedback from 2nd Coach
W3 Group, LLC
Our Intent Today…
• To demonstrate
the core routines
• give you something
to think about and…
of TK,
• allow you to
compare to your
current way of
working.
W3 Business Systems
© Mike Rother
W3 Group, LLC
17
The Pattern of the Improvement
Kata
W3 Business Systems
© Mike Rother
W3 Group, LLC
18
W3 Business Systems
© Mike Rother
19
W3 Group, LLC
Challenge creates alignment between
different functions / departments
toward a Shared Objective
W3 Business Systems
© Mike Rother
W3 Group, LLC
The Roles
Manager
Manager Advises
and Supports
W3 Business Systems
Supervisor
Supervisor Owns the Target
Condition.
© Mike Rother
W3 Group, LLC
21
COACHING KATA
Second Cycle
and Beyond
The Five Questions
1)
What is the Target Condition?
2)
What is the Actual Condition now?
-------- Turn
Turn
Card
Over -----------------------Card
Over ------------------>
3)
4)
5)
Reflect on the Last Step Taken
What Obstacles do you think are preventing
you from reaching the target condition?
Which One are you addressing now?
What is your Next Step (next PDCA/experiment)
What do you Expect?
When can we go and see what we
have learned from taking that step?
Because you don’t actually know
what the result of a step will be!
1) What was your Last Step?
2) What did you Expect?
3) What Actually Happened?
4) What did you Learn?
Return --------->
W3 Business Systems
© Mike Rother
W3 Group, LLC
Daily SFM Coaching Routine
5. Delivery
1. Safety
last 24h / next 24h
Where are we in relation to
the goal? (KPI)
Use questions to inquire
about the problem
(examples)
last 24h / next 24h
Go and See as much as
you can.
Problem
4. Cost
last 24h / next 24h
Where are we in relation to
the goal? (KPI)
Did we understand the problem?
Can you explain the problem?
Do we need to go & see to fully
understand?
What can we do immediately?
Do you see any benefit in writing
this down?
What can I do to help?
How can I help?
2. Attendance
last 24h / next 24h
How much capacity do we need and
have?
Are people working where we need
them?
If you encounter:
= No issue, move on to next point of the
routine
= Move to the problem section , investigate
W3 Business Systems
3. Quality
last 24h / next 24h
Where are we in relation to
the goal? (KPI)
REV 2.2
W3 Group, LLC
Our Intent Today…
• To demonstrate
the core routines
• give you something
to think about and…
of TK,
• allow you to
compare to your
current way of
working.
W3 Business Systems
© Mike Rother
W3 Group, LLC
24