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Productivity Press

Quality Insider

Kata and Training Within Industry Sustain Change in Any Organization

Explained in the book The Seven Kata: Toyota Kata, TWI, and Lean Training

Published: Friday, June 29, 2012 - 10:14

Patrice Boutier and Conrad Soltero wrote The Seven Kata: Toyota Kata, TWI, and Lean Training, (Productivity Press, 2012), to show how Training Within Industry (TWI) modules and kata skills together make a great application plan for sustaining change in a corporation.

The Japanese term, kata, has been defined as “a way of doing something,” “a pattern, form, routine, or method,” and “a training drill.”

“A kata is a routine or method that is practiced and used time and again, whereby it becomes second nature,” explains Mike Rother, author of Toyota Kata (McGraw-Hill, 2009) in a Quality Digest interview. “The intention is to learn a desired habit, skill, and mindset.”

It’s not the tools used in lean applications but the skills and mindset developed through kata that enable people to improve and sustain changes, says Boutier in an interview video by CRC Press. “Many companies have a problem with sustaining TWI and lean and taking it to the next level. What we do in the book is show the reader how to apply the Toyota kata modules that Mike Rother has come up with and use them for cultural modification and that then leads to applying TWI modules and understanding how those seven kata work together to make sustainable change in a corporation. Understand that these skills, these kata, are really what lean is about.

“Combining kata with TWI really makes a change so that culture can begin to move forward,” adds Boutier. “It doesn’t happen right away. It takes practice.”

book

The Seven Kata:
• Describes the roles of teaching, coaching, and training for lean
• Explains gemba walks, genchi gembutsu, and plan-do-check-act (PDCA)
• Reveals the different kata inherent in the three major TWI courses and the TWI job safety course
• Explains the value stream analysis relationship to the kata and the kata’s relationship to TWI job instruction
• Demonstrates how to use kata to solve the problems identified in the value stream analysis while simultaneously conditioning employees’ adaptive thinking patterns
• Includes helpful guidelines for coaching a kata and for training job instruction
• The authors highlight mistakes they have experienced or witnessed so you can avoid the same pitfalls.

Content

Weapons for the Economic Warrior
The Improvement Kata: Kaizen
The Nested Job Instruction Kata: Learn to Teach
The Coaching Kata: Teaching to Learn
The Problem-Solving Kata: Seek to Understand Kata
The Job Relations Kata: The Cultural Fortifier
Job Safety Kata: The Duplex Kata
The Job Methods Kata: Kipling’s Kata
Submit to the Kata

About Conrad Soltero and Patrice Boutier

Conrad Soltero and Patrice Boutier are field engineers and business solutions advisors with the Texas Manufacturing Assistance Center (TMAC), which works in partnership with the manufacturing community and the College of Engineering, University of Texas at El Paso to deliver training and hands-on technical assistance that improve efficiency, quality, and productivity.

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About The Author

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Productivity Press

For more than 25 years, Productivity Press has developed the largest catalog available anywhere of publications and learning tools about lean methodology, continuous improvement, and operational excellence. It is currently the premier source of authoritative information on organizational transformation. Productivity Press is an imprint of CRC Press, a premier global publisher of science, technology, and medical resources. Its aim is to broaden thinking and advance understanding in the sciences, providing researchers, academics, professionals, and students with the tools they need to share ideas and realize their potential. CRC Press is a member of Taylor & Francis Group, an informa business.