Decoding the DNA of the Toyota Production System
Spear and Bowen, 1999
What an insightful document from 21 years ago! Mike Rother mentions this paper on page 7 of “Toyota Kata” (2009). Take a look at the fourth of “The Four Rules” in the grey box on “page 98” of the 10 pages of text.
In the Oxford Dictionary, mastery is defined as comprehensive knowledge or skill in a particular subject or activity.
What we now know as the two “Toyota Kata patterns” were identified and brought together as a result of Mike Rother’s research in the 5 years preceding the release of Toyota Kaya (McGraw Hill, 2009). During that research Mike identified something that had been in existence for a long time but was somewhat hidden from view as it was embedded in daily behaviours.
Putting a name to the improvement pattern (Improvement Kata) and a name to the coaching pattern (Coaching Kata) helped “isolate” these behaviours and made what was implicit to few explicit to many. This has helped in creating practice routines the ultimate aim being make such patterns of behaviour implicit in ourselves and our Learners.
Ben and I, both as individuals within our own organisation and with our clients, have been practising the Toyota Kata patterns since 2011. We feel it is premature to try and define mastery. We are still often consciously trying to make something unconscious that we understand Toyota people and others have been doing subconsciously for many many years previous.
One might say “ask a Toyota person” (about “mastery”). I’ve tried that and that person had great difficulty articulating such behaviours but I see it in them every day that I work with them.
So for now “watch this space”. As “Toyota Kata Mastery” becomes more evident in ourselves and the people we work with we will update this page!
Brad Byrnes , Chief Operating Officer Parkes Shire Council
Andrew Francis, Chief Operating Officer Parkes Shire Council
Throughout this project Oscar has involved the experienced staff in the building of the knowledge and skill material, increasing the likelihood of a sustainable system, owned by our people.
Oscar has helped us develop a system of learning, in our own often fast paced environment that has the required consistency to ensure the quality required with the flexibility to accommodate the needs of the individual. He has made the step by step requirements clear, and reliably follows up on the tasks he is driving, carefully insisting and helping us reach each step of the project.
Baiada Poultry Garth Oakroot, Site Manager, Hanwood Feedmill
We had a wonderful 2 weeks of training on TWI covering JI and JR. JI is a very effective training methodology that we can apply in many areas. We were completely convinced that it can helps in shorten our training lead time, improve the efficiency and quality in our worker’s performance. How good if we can get to know this earlier!!
JR on another note is very much a soft skill training. On the first perception, it seems like a general knowledge; something that we were being taught in any leadership training. However similarly to JI; there’s a pattern of learning that we need to develop that is matter. Most of the time we know what should be done but we just failed to do so. JR will definitely address that as we will handle the issue steps by steps till that become a habits.
Oscar is a seasoned trainer, very knowledgeable in the subject. He carried out the training in his most professional self and accept no nonsense from the group. He has a sharp observation skill and always able to bring out the best from each student.
Schneider Electric (Malaysia) Chin Wei KUE, SC Performance Manager – Process Domain
Melissa Smith, Kata in the Classroom, Lean HR Summit- Austin, Texas, 12/9/19.
My deepest thanks!!
Marissa Brinkman – Fishback Financial Corporation
John Batten - President, New Hampshire Industries USA