Kata is the Japanese word that means form. A Kata is a detailed choreographed ritual of movements traditionally practiced in martial arts. The skills are handed down from master to student over many generations. Kata is a pattern of behavior, when practiced repetitively it becomes second nature. It is commonly referred to the Toyota Kata and is defined as an integral tool of change throughout the whole company. The key to Kata is habit. In Lean terms, Kata is a routine, standardized, synchronised process, it includes Improvement Kata (IK) and Coaching Kata (CK).
“The systematic pursuit of desired conditions by utilizing human capabilities in a concerted way.”
Mike Rother, author Toyota Kata
Improvement Kata
It is based on a four step procedure:
- Understand the Direction
- Grasp the Current Condition
- Define the Next Target Condition
- PDCA - Plan Do Check - toward the Target Condition
- Understand the Direction
- Grasp the Current Condition
- Define the Next Target Condition
- PDCA - Plan Do Check - toward the Target Condition
Simple Kata routines in the laboratory could include:
- Gemba - Regular Gemba ensures that a Lean culture is being implemented through practice and training. For instance, observe 5S, Kaizen projects and other lean initiatives in the lab.
- Sustainment - sustain successful Kaizen programs - delegate responsibilities and implement regular audits.
- Repeat and implement - replicate sustained improvements in other processes.
- Bottom-up Improvement - improvement that happens outside of a Kaizen event, start small and build small incremental changes towards improvement. This may involve something simple like relocating an instrument to streamline a process and reduce muda (waste).
Coaching Kata
The Coaching Kata supports Improvement Kata by encouraging learning and training to improve the current condition and ensure that porgress is being made townards the target. Coaching Kata is instrumental in the fourth step of the Improvement Kata, PDCA (Plan, Do, Check, Act) towards attaining the Target Condition. The Coaching Kata question cards are an excellent resource to support IK.
The IK Reference Guide
by Mike Rother
Further information and resources
I love Lego so I highly recommend these Kata presentations by Hakan Forss.
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