Toyota Kata

Question 1

When conducting a PDCA experiment, you should always:

Answer 1

Predict what will happen, run the experiment, and check the results against your prediction

Question 2

Success in the Improvement Kata means that:

Answer 2

You increase your scientific-thinking skill while simultaneously improving a process

Question 3

Each time you run a PDCA cycle, you should expect to:

Answer 3

Advance your Threshold of Knowledge, either through a successful trial or a failure

Question 4

When we discuss ‘Kata’ we are talking about:

Answer 4

Structured practice routines to develop a new skill

Question 5

Which of the following is most effective for developing new habits:

Answer 5

Practice for a short time, but frequently

Question 6

Which of the following does NOT describe a “Kata”?

Answer 6

Telling people what to do

Question 7

In order to start creating effective problem solvers, we should:

Answer 7

Combine a scientific thinking pattern with practice routines

Question 8

The Improvement Kata is:

Answer 8

1) A scientific pattern to teach and learn that develops and mobilizes people’s capability to meet challenges
2) A foundation that makes lean tools work as intended
3) A model of Toyota’s underlying thinking for improving and evolving throughout the organisation

Question 9

The steps of the Improvement Kata model are:

Answer 9

1)Understand the Challenge,
2) Grasp the Current Condition,
3) Establish the Next Target Condition,
4) Move Toward the Target Condition via Experimenting

Question 10

A key ingredient for trying to create a new culture, or a new way of doing things, is:

Answer 10

A consistent set of routines

Question 11

When getting started with the Improvement Kata, you should:

Answer 11

Have a basic understanding of how people learn and acquire new skills

Question 12

Fundamental elements of acquiring new skills are:

Answer 12

Challenge - Starter Kata - Frequent practive - Coaching - Self-Efficacy

Question 13

You find value stream mapping within the Improvement Kata because:

Answer 13

A future state value stream map can provide the necessary Challenge

Question 14

The Learner uses the Learner’s Storyboard to:

Answer 14

Prepare for a Coaching Cycle

Question 15

Start with the Challenge in the Improvement Kata because:

Answer 15

The Challenge provides the purpose and direction for improvement

Question 16

What is the purpose of process analysis / grasping the Current Condition?

Answer 16

To provide the information for establishing an appropriate next Target Condition

Question 17

The starter kata for grasping the Current Condition includes:

Answer 17

Calculate Takt time, create a process block diagram, identify machine constraints, calculate stable manning levels, and graph process output

Question 18

Why do we calculate a Takt Time for Amalgamated’s Small Box Assembly at this point?

Answer 18

To help us understand where we currently are compared to customer demand

Question 19

When we calculate a Planned Cycle Time, we are:

Answer 19

Recognizing waste exists but ensuring we will satisfy customer demand

Question 20

Creating the Process Block Diagram:

Answer 20

Allows us to get an understanding of how the process flows

Question 21

Make a run chart of process output cycles in order to:

Answer 21

Understand the lowest repeatable cycle time compared to takt, and the amount of variation in the process

Question 22

Equipment constraints are considered during the Current Condition Analysis:

Answer 22

To help identify potential Obstacles to achieving the First Target Condition

Question 23

Daily Coaching Cycles are:

Answer 23

A way to get feedback and correction during the process and also to reinforce a scientific way of thinking

Question 24

Grasping the Current Condition is:

Answer 24

Continues naturally as you experiment, learn, and improve the process

Question 25

When establishing a process Target Condition you should:

Answer 25

Describe the desired operating pattern + the desired output metric + put a specific achieve-by date on it

Question 26

When you establish a Target Condition, it is important to:

Answer 26

Set a time frame/date for when the Target Condition will be achieved

Question 27

What is always unclear when you are working with Target Conditions?

Answer 27

The path to the Target Condition

Question 28

As you start your experiments, or PDCA cycles, you should:

Answer 28

Understand clearly which Obstacle you are experimenting against

Question 29

The Obstacle Parking Lot should:

Answer 29

Continue to be updated as you move forward and learn more

Question 30

Will the Current Condition change every time you have a Coaching Cycle?

Answer 30

No. Some PDCA experiments will not be successful, but the team will have learned something from the experiment

Question 31

Each time you run a PDCA cycle, you should expect to:

Answer 31

Advance your Threshold of Knowledge, either through a successful trial or a failure

Question 32

An experiment is scientific if:

Answer 32

An expectation is formulated and the outcome is unknown