The documents describe a manufacturing cell at ACME that is currently over capacity and inefficient. The target condition is to reduce floor space by 50% and machinery by 50% while improving productivity, quality, and eliminating overtime by January 1, 2017. The current condition details metrics such as parts per labor hour, scrap percentage, cycle times, and other process characteristics that indicate issues with excess capacity at hobbing and milling machines leading to high variability. Charts and a summary sheet provide additional data on the manufacturing cell's performance.

1. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
01
Storyboard and Kata forms to
supplement the Coaching Scripts
1. Learner’s Story Board, slides are 36” x 48“,
Landscape
2. All other forms are 8.5”x11”, OR 11” X17”
Landscape
Supplement Lecture 7b
Rev. 09.21.2016

2. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
02
Focus Process: Challenge:
Target Condition
Achieve by: 06.10.2016
Current Condition
It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less
floor space, operating 2 shifts with 50% of the machinery, so we can achieve:
50 PPLH, <3.5% Scrap, with No Overtime
Process Metrics Process Metrics
Outcome Metrics
Outcome Metrics
F/A - Pack
Mill 8
Mill 7
Mill 6
Mill 5
Mill 4
Mill 3
Mill 2
Mill 1
CNC 2
CNC 1
Shaper 6
Shaper 5
Shaper 4
Shaper 3
Shaper 2
Shaper 1
Hob 18
Hob 17
Hob 16
Hob 15
Hob 14
Hob 13
Hob 12
Hob 11
Hob 10
Hob 9
Hob 8
Hob 7
Hob 6
Hob 5
Hob 4
Hob 3
Hob 2
Hob 1
Hob 0
Hob 1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHER PROCESS METRICS:
Mill Reliability is 80%
Overtime is due to machine reliability at Turning Mills 1,7, & 8
NOTES AND OBSERVATIONS
PROCESS CHARACTERISTICS:
We have excess capacity and high variation in machine cycle
with our Hob Machines. Hob 18 cycle time exceeds Takt Time
We have excess capacity and high variation in machine cycle
with our Turning Mill Machines.
PPLH = 27.5
Scrap = 6.7%
OverTime = 8%
First Pass Yield = 93%
Exit Cycle Var(Pack) = 10 s +/- 12%
Hob 18 Lowest Repeatable Hi Var = +195%
Lo Var = - 24%= 14 seconds
Takt Time = 12.3 seconds
Planned Cycle Time= 10.5 Seconds
Number of Shifts = 3
Number of Operators = 10
CURRENT CONDITION SUMMARY SHEET
Outcome Metrics (See Charts)
Process Stability:
ACME Machining Cell
First Pass Yield > 98%
Mill Reliability > 90%
PPLH > 50
Scrap < 3.5%
Overtime = 0%
Scene 1 Script

3. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
03
Target Condition
Achieve by: 06.10.2016
Current Condition
Process Metrics Process Metrics
Outcome Metrics Outcome Metrics
F/A - Pack
Mill 8
Mill 7
Mill 6
Mill 5
Mill 4
Mill 3
Mill 2
Mill 1
CNC 2
CNC 1
Shaper 6
Shaper 5
Shaper 4
Shaper 3
Shaper 2
Shaper 1
Hob 18
Hob 17
Hob 16
Hob 15
Hob 14
Hob 13
Hob 12
Hob 11
Hob 10
Hob 9
Hob 8
Hob 7
Hob 6
Hob 5
Hob 4
Hob 3
Hob 2
Hob 1
Hob 0
Hob 1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHER PROCESS METRICS:
Mill Reliability is 80%
Overtime is due to machine reliability at Turning Mills 1,7, & 8
NOTES AND OBSERVATIONS
PROCESS CHARACTERISTICS:
We have excess capacity and high variation in machine cycle
with our Hob Machines. Hob 18 cycle time exceeds Takt Time
We have excess capacity and high variation in machine cycle
with our Turning Mill Machines.
PPLH = 27.5
Scrap = 6.7%
OverTime = 8%
First Pass Yield = 93%
Exit Cycle Var(Pack) = 10 s +/- 12%
Hob 18 Lowest Repeatable Hi Var = +195%
Lo Var = - 24%= 14 seconds
Takt Time = 12.3 seconds
Planned Cycle Time= 10.5 Seconds
Number of Shifts = 3
Number of Operators = 10
CURRENT CONDITION SUMMARY SHEET
Outcome Metrics (See Charts)
Process Stability:
First Pass Yield > 95%
Mill Reliability > 85%
PPLH > 37.5
Scrap < 5%
Overtime < 10%
Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less
floor space, operating 2 shifts with 50% of the machinery, so we can achieve:
50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell
Scene 2 Script

4. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
04
Target Condition
Achieve by: 06.10.2016
Current Condition
Process Metrics Process Metrics
Outcome Metrics Outcome Metrics
F/A - Pack
Mill 8
Mill 7
Mill 6
Mill 5
Mill 4
Mill 3
Mill 2
Mill 1
CNC 2
CNC 1
Shaper 6
Shaper 5
Shaper 4
Shaper 3
Shaper 2
Shaper 1
Hob 18
Hob 17
Hob 16
Hob 15
Hob 14
Hob 13
Hob 12
Hob 11
Hob 10
Hob 9
Hob 8
Hob 7
Hob 6
Hob 5
Hob 4
Hob 3
Hob 2
Hob 1
Hob 0
Hob 1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHER PROCESS METRICS:
Mill Reliability is 80%
Overtime is due to machine reliability at Turning Mills 1,7, & 8
NOTES AND OBSERVATIONS
PROCESS CHARACTERISTICS:
We have excess capacity and high variation in machine cycle
with our Hob Machines. Hob 18 cycle time exceeds Takt Time
We have excess capacity and high variation in machine cycle
with our Turning Mill Machines.
PPLH = 27.5
Scrap = 6.7%
OverTime = 8%
First Pass Yield = 93%
Exit Cycle Var(Pack) = 10 s +/- 12%
Hob 18 Lowest Repeatable Hi Var = +195%
Lo Var = - 24%= 14 seconds
Takt Time = 12.3 seconds
Planned Cycle Time= 10.5 Seconds
Number of Shifts = 3
Number of Operators = 10
CURRENT CONDITION SUMMARY SHEET
Outcome Metrics (See Charts)
Process Stability:
First Pass Yield > 95%
Mill Reliability > 85%
PPLH > 37.5
Scrap < 5%
Overtime < 10%
Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less
floor space, operating 2 shifts with 50% of the machinery, so we can achieve:
50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell
Scene 3 Script
Obstacle
1
2
3
4
5
Workload on operators
Scrap
OBSTACLES PARKING LOT
How will you measure that?
Less number of Hobs
Less number of Turning Mills

5. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
05
Target Condition
Achieve by: 06.10.2016
Current Condition
Process Metrics Process Metrics
Outcome Metrics Outcome Metrics
PDCA #0 -Slide 13
F/A - Pack
Mill 8
Mill 7
Mill 6
Mill 5
Mill 4
Mill 3
Mill 2
Mill 1
CNC 2
CNC 1
Shaper 6
Shaper 5
Shaper 4
Shaper 3
Shaper 2
Shaper 1
Hob 18
Hob 17
Hob 16
Hob 15
Hob 14
Hob 13
Hob 12
Hob 11
Hob 10
Hob 9
Hob 8
Hob 7
Hob 6
Hob 5
Hob 4
Hob 3
Hob 2
Hob 1
Hob 0
Hob 1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHER PROCESS METRICS:
Mill Reliability is 80%
Overtime is due to machine reliability at Turning Mills 1,7, & 8
NOTES AND OBSERVATIONS
PROCESS CHARACTERISTICS:
We have excess capacity and high variation in machine cycle
with our Hob Machines. Hob 18 cycle time exceeds Takt Time
We have excess capacity and high variation in machine cycle
with our Turning Mill Machines.
PPLH = 27.5
Scrap = 6.7%
OverTime = 8%
First Pass Yield = 93%
Exit Cycle Var(Pack) = 10 s +/- 12%
Hob 18 Lowest Repeatable Hi Var = +195%
Lo Var = - 24%= 14 seconds
Takt Time = 12.3 seconds
Planned Cycle Time= 10.5 Seconds
Number of Shifts = 3
Number of Operators = 10
CURRENT CONDITION SUMMARY SHEET
Outcome Metrics (See Charts)
Process Stability:
First Pass Yield > 95%
Mill Reliability > 85%
PPLH > 37.5
Scrap < 5%
Overtime < 10%
Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less
floor space, operating 2 shifts with 50% of the machinery, so we can achieve:
50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell
Scene 4 Script
Fi. 5

6. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
06
Target Condition
Achieve by: 06.10.2016
Current Condition
Process Metrics Process Metrics
Outcome Metrics Outcome Metrics
PDCA #1 -Slide 14
F/A - Pack
Mill 8
Mill 7
Mill 6
Mill 5
Mill 4
Mill 3
Mill 2
Mill 1
CNC 2
CNC 1
Shaper 6
Shaper 5
Shaper 4
Shaper 3
Shaper 2
Shaper 1
Hob 18
Hob 17
Hob 16
Hob 15
Hob 14
Hob 13
Hob 12
Hob 11
Hob 10
Hob 9
Hob 8
Hob 7
Hob 6
Hob 5
Hob 4
Hob 3
Hob 2
Hob 1
Hob 0
Hob 1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHER PROCESS METRICS:
Mill Reliability is 80%
Overtime is due to machine reliability at Turning Mills 1,7, & 8
NOTES AND OBSERVATIONS
PROCESS CHARACTERISTICS:
We have excess capacity and high variation in machine cycle
with our Hob Machines. Hob 18 cycle time exceeds Takt Time
We have excess capacity and high variation in machine cycle
with our Turning Mill Machines.
PPLH = 27.5
Scrap = 6.7%
OverTime = 8%
First Pass Yield = 93%
Exit Cycle Var(Pack) = 10 s +/- 12%
Hob 18 Lowest Repeatable Hi Var = +195%
Lo Var = - 24%= 14 seconds
Takt Time = 12.3 seconds
Planned Cycle Time= 10.5 Seconds
Number of Shifts = 3
Number of Operators = 10
CURRENT CONDITION SUMMARY SHEET
Outcome Metrics (See Charts)
Process Stability:
Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less
floor space, operating 2 shifts with 50% of the machinery, so we can achieve:
50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell
Scene 5 Script

7. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
07
Target Condition
Achieve by: 06.10.2016
Current Condition
Process Metrics Process Metrics
Outcome Metrics Outcome Metrics
PDCA #2 -Slide 15
F/A - Pack
Mill 8
Mill 7
Mill 6
Mill 5
Mill 4
Mill 3
Mill 2
Mill 1
CNC 2
CNC 1
Shaper 6
Shaper 5
Shaper 4
Shaper 3
Shaper 2
Shaper 1
Hob 18
Hob 17
Hob 16
Hob 15
Hob 14
Hob 13
Hob 12
Hob 11
Hob 10
Hob 9
Hob 8
Hob 7
Hob 6
Hob 5
Hob 4
Hob 3
Hob 2
Hob 1
Hob 0
Hob 1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHER PROCESS METRICS:
Mill Reliability is 80%
Overtime is due to machine reliability at Turning Mills 1,7, & 8
NOTES AND OBSERVATIONS
PROCESS CHARACTERISTICS:
We have excess capacity and high variation in machine cycle
with our Hob Machines. Hob 18 cycle time exceeds Takt Time
We have excess capacity and high variation in machine cycle
with our Turning Mill Machines.
PPLH = 27.5
Scrap = 6.7%
OverTime = 8%
First Pass Yield = 93%
Exit Cycle Var(Pack) = 10 s +/- 12%
Hob 18 Lowest Repeatable Hi Var = +195%
Lo Var = - 24%= 14 seconds
Takt Time = 12.3 seconds
Planned Cycle Time= 10.5 Seconds
Number of Shifts = 3
Number of Operators = 10
CURRENT CONDITION SUMMARY SHEET
Outcome Metrics (See Charts)
Process Stability:
PDCA #3 -Slide 16
Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less
floor space, operating 2 shifts with 50% of the machinery, so we can achieve:
50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell
Scene 6 Script

8. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
08
Target Condition
Achieve by: 06.10.2016
Current Condition
Process Metrics Process Metrics
Outcome Metrics Outcome Metrics
PDCA #2 -Slide 15
F/A - Pack
Mill 8
Mill 7
Mill 6
Mill 5
Mill 4
Mill 3
Mill 2
Mill 1
CNC 2
CNC 1
Shaper 6
Shaper 5
Shaper 4
Shaper 3
Shaper 2
Shaper 1
Hob 18
Hob 17
Hob 16
Hob 15
Hob 14
Hob 13
Hob 12
Hob 11
Hob 10
Hob 9
Hob 8
Hob 7
Hob 6
Hob 5
Hob 4
Hob 3
Hob 2
Hob 1
Hob 0
Hob 1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHER PROCESS METRICS:
Mill Reliability is 80%
Overtime is due to machine reliability at Turning Mills 1,7, & 8
NOTES AND OBSERVATIONS
PROCESS CHARACTERISTICS:
We have excess capacity and high variation in machine cycle
with our Hob Machines. Hob 18 cycle time exceeds Takt Time
We have excess capacity and high variation in machine cycle
with our Turning Mill Machines.
PPLH = 27.5
Scrap = 6.7%
OverTime = 8%
First Pass Yield = 93%
Exit Cycle Var(Pack) = 10 s +/- 12%
Hob 18 Lowest Repeatable Hi Var = +195%
Lo Var = - 24%= 14 seconds
Takt Time = 12.3 seconds
Planned Cycle Time= 10.5 Seconds
Number of Shifts = 3
Number of Operators = 10
CURRENT CONDITION SUMMARY SHEET
Outcome Metrics (See Charts)
Process Stability:
PDCA #4 -Slide 17
Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less
floor space, operating 2 shifts with 50% of the machinery, so we can achieve:
50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell
Scene 7 Script

9. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
09
Target Condition
Achieve by: 06.10.2016
Current Condition
Process Metrics Process Metrics
Outcome Metrics Outcome Metrics
PDCA #5 -Slide 19
PDCA #4 - Slide 18
F/A - Pack
Mill 8
Mill 7
Mill 6
Mill 5
Mill 4
Mill 3
Mill 2
Mill 1
CNC 2
CNC 1
Shaper 6
Shaper 5
Shaper 4
Shaper 3
Shaper 2
Shaper 1
Hob 18
Hob 17
Hob 16
Hob 15
Hob 14
Hob 13
Hob 12
Hob 11
Hob 10
Hob 9
Hob 8
Hob 7
Hob 6
Hob 5
Hob 4
Hob 3
Hob 2
Hob 1
Hob 0
Hob 1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHER PROCESS METRICS:
Mill Reliability is 80%
Overtime is due to machine reliability at Turning Mills 1,7, & 8
NOTES AND OBSERVATIONS
PROCESS CHARACTERISTICS:
We have excess capacity and high variation in machine cycle
with our Hob Machines. Hob 18 cycle time exceeds Takt Time
We have excess capacity and high variation in machine cycle
with our Turning Mill Machines.
PPLH = 27.5
Scrap = 6.7%
OverTime = 8%
First Pass Yield = 93%
Exit Cycle Var(Pack) = 10 s +/- 12%
Hob 18 Lowest Repeatable Hi Var = +195%
Lo Var = - 24%= 14 seconds
Takt Time = 12.3 seconds
Planned Cycle Time= 10.5 Seconds
Number of Shifts = 3
Number of Operators = 10
CURRENT CONDITION SUMMARY SHEET
Outcome Metrics (See Charts)
Process Stability:
Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less
floor space, operating 2 shifts with 50% of the machinery, so we can achieve:
50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell
Scene 8 Script

10. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
10
Target Condition
Achieve by: 06.10.2016
Current Condition
Process Metrics Process Metrics
Outcome Metrics Outcome Metrics
PDCA #6 -Slide 20
PDCA #4 – Slide 18
F/A - Pack
Mill 8
Mill 7
Mill 6
Mill 5
Mill 4
Mill 3
Mill 2
Mill 1
CNC 2
CNC 1
Shaper 6
Shaper 5
Shaper 4
Shaper 3
Shaper 2
Shaper 1
Hob 18
Hob 17
Hob 16
Hob 15
Hob 14
Hob 13
Hob 12
Hob 11
Hob 10
Hob 9
Hob 8
Hob 7
Hob 6
Hob 5
Hob 4
Hob 3
Hob 2
Hob 1
Hob 0
Hob 1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHER PROCESS METRICS:
Mill Reliability is 80%
Overtime is due to machine reliability at Turning Mills 1,7, & 8
NOTES AND OBSERVATIONS
PROCESS CHARACTERISTICS:
We have excess capacity and high variation in machine cycle
with our Hob Machines. Hob 18 cycle time exceeds Takt Time
We have excess capacity and high variation in machine cycle
with our Turning Mill Machines.
PPLH = 27.5
Scrap = 6.7%
OverTime = 8%
First Pass Yield = 93%
Exit Cycle Var(Pack) = 10 s +/- 12%
Hob 18 Lowest Repeatable Hi Var = +195%
Lo Var = - 24%= 14 seconds
Takt Time = 12.3 seconds
Planned Cycle Time= 10.5 Seconds
Number of Shifts = 3
Number of Operators = 10
CURRENT CONDITION SUMMARY SHEET
Outcome Metrics (See Charts)
Process Stability:
Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less
floor space, operating 2 shifts with 50% of the machinery, so we can achieve:
50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell
Scene 9 Script

11. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
11
Target Condition
Achieve by: 06.10.2016
Current Condition
Process Metrics Process Metrics
Outcome Metrics Outcome Metrics
PDCA #6 -Slide 21
PDCA #7 – Slide 22
F/A - Pack
Mill 8
Mill 7
Mill 6
Mill 5
Mill 4
Mill 3
Mill 2
Mill 1
CNC 2
CNC 1
Shaper 6
Shaper 5
Shaper 4
Shaper 3
Shaper 2
Shaper 1
Hob 18
Hob 17
Hob 16
Hob 15
Hob 14
Hob 13
Hob 12
Hob 11
Hob 10
Hob 9
Hob 8
Hob 7
Hob 6
Hob 5
Hob 4
Hob 3
Hob 2
Hob 1
Hob 0
Hob 1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHER PROCESS METRICS:
Mill Reliability is 80%
Overtime is due to machine reliability at Turning Mills 1,7, & 8
NOTES AND OBSERVATIONS
PROCESS CHARACTERISTICS:
We have excess capacity and high variation in machine cycle
with our Hob Machines. Hob 18 cycle time exceeds Takt Time
We have excess capacity and high variation in machine cycle
with our Turning Mill Machines.
PPLH = 27.5
Scrap = 6.7%
OverTime = 8%
First Pass Yield = 93%
Exit Cycle Var(Pack) = 10 s +/- 12%
Hob 18 Lowest Repeatable Hi Var = +195%
Lo Var = - 24%= 14 seconds
Takt Time = 12.3 seconds
Planned Cycle Time= 10.5 Seconds
Number of Shifts = 3
Number of Operators = 10
CURRENT CONDITION SUMMARY SHEET
Outcome Metrics (See Charts)
Process Stability:
Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less
floor space, operating 2 shifts with 50% of the machinery, so we can achieve:
50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell
Scene 10 Script

12. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
12
KATA PDCA CYCLES RECORD(each row = one experiment)
Date: 05-26-16 Process: Hob Machining of gear
Obstacle: Don’t know what it will take to get 10 Hobs running while
maintain quality at 7 min cycle time
Process Metric: Number of Hob machines operating
Learner: Terry Coach: John
Date, Time, Type, Step & Metric What do you expect?
Coaching Cycle
Experiment
What happened?
(observe)
What did you learn?
(what you expected? / what happened?)
DATE:
5-26-16
Talk with setup and
maintenance to see
the status of the
machines that have
been down longest to
see if we are waiting
on parts to be made or
on order. And I want to
get an estimate of
when they will be
ready to test the two
Hob machines that are
down.
I expect to learn that
we have been waiting
for parts and to learn
when machines will be
ready to test
TIME:
11:00 AM
“Go See” X
“Exploratory”
“Hypothesis”
DATE:
TIME:
“Go See”
“Exploratory”
“Hypothesis”

13. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
13
KATA PDCA CYCLES RECORD(each row = one experiment)
Date: 05-26-16 Process: Hob Machining of gear
Obstacle: Don’t know what it will take to get 10 Hobs running while
maintain quality at 7 min cycle time
Process Metric: Number of Hob machines operating
Learner: Terry Coach: John
Date, Time, Type, Step & Metric What do you expect?
Coaching Cycle
Experiment
What happened?
(observe)
What did you learn?
(what you expected? / what happened?)
DATE:
5-26-16
Talk with setup and
maintenance to see
the status of the
machines that have
been down longest to
see if we are waiting
on parts to be made or
on order and estimate
of when they will be
ready to test the two
Hob machines that are
down.
I expect to learn that
we have been waiting
for parts and to learn
when machines will be
ready to test
TIME:
11:00 AM
“Go See” X
“Exploratory”
“Hypothesis”
DATE:
5-27-16
I will collect all hourly
computer reports from
each Hob on first and
second shift and
compare them looking
for any changes in
quality standards. I will
track how many cycles
of the machines to see
if they fail before the
end of a 50 piece
sample run on this
shift.
I will learn how many
Hobs can run quality
pieces consistently and
if we need to shorten
number of cycles
between shifts.
TIME:
10:30 AM
“Go See” x
“Exploratory”
“Hypothesis”

14. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
14
KATA PDCA CYCLES RECORD(each row = one experiment)
Date: 05-26-16 Process: Hob Machining of gear
Obstacle: Don’t know what it will take to get 10 Hobs running while
maintain quality at 7 min cycle time
Process Metric: Number of Hob machines operating
Learner: Terry Coach: John
Date, Time, Type, Step & Metric What do you expect?
Coaching Cycle
Experiment
What happened?
(observe)
What did you learn?
(what you expected? / what happened?)
DATE:
5-26-16
Talk with setup and
maintenance to see
the status of the
machines that have
been down longest to
see if we are waiting
on parts to be made or
on order and estimate
of when they will be
ready to test the two
Hob machines that are
down.
I expect to learn that
we have been waiting
for parts and to learn
when machines will be
ready to test
TIME:
11:00 AM
“Go See” X
“Exploratory”
“Hypothesis”
DATE:
5-27-16
I will collect all hourly
Gleason reports from
each Hob on first and
second shift and
compare them looking
for any changes in
quality standards. I will
track how many cycles
of the machines to see
if they fail before the
end of a 50 piece
sample run on this
shift.
I will learn how many
Hobs can run quality
pieces consistently and
if we need to shorten
number of cycles
between shifts.
10 out of 18 machines
we started with on 5-27-
16 all are still running
quality pieces after an
average of fifty cycles,
and 50 quality parts
have been produced. I
wanted to put all ten
Hobs through a
complete 8 hour shift,
however, we are
waiting on two out of
the ten Hobs to be fixed
for production.
That we have 10 out of 18
machines that are
consistently running
quality pieces
If I had the opportunity to
conduct this PDCA again,
I wouldn't do anything
differently.
I learned we have enough
Hobs running to meet
goal of 2200 pieces per
shift.
TIME:
10:30 AM
“Go See” x
“Exploratory”
“Hypothesis”

15. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
15
KATA PDCA CYCLES RECORD(each row = one experiment)
Date: 5-31-16 Process: Hob Machining of gears
Obstacle: We don’t know how the operators will cover work load
going from 3 shifts to 2 shifts
Process Metric: Save time checking pieces
Learner: Terry Coach: John
Date, Time, Type, Step & Metric What do you expect?
Coaching Cycle
Experiment
What happened?
(observe)
What did you learn?
(what you expected? / what happened?)
DATE:
5-31-16
Work with operators to
find the best place for
second check station
at end of line
To help reduce the
time for checking
pieces, and see if we
need more gages and
record the time
walking to check parts
I expect to find a place
to set up at second
check station.
It will help reduce time
walking back and forth
to check parts.TIME:
11:00 AM
“Go See”
“Exploratory” X
“Hypothesis”
DATE:
TIME:
“Go See”
“Exploratory”
“Hypothesis”

16. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
16
KATA PDCA CYCLES RECORD(each row = one experiment)
Date: 5-31-16 Process: Hob Machining of gears
Obstacle: We don’t know how the operators will cover work load
going from 3 shifts to 2 shifts
Process Metric: Save time checking pieces
Learner: Terry Coach: John
Date, Time, Type, Step & Metric What do you expect?
Coaching Cycle
Experiment
What happened?
(observe)
What did you learn?
(what you expected? / what happened?)
DATE:
5-31-16
Work with operators to
find the best place for
second check station
at end of line
To help reduce the
time for checking
pieces, and see if we
need more gages and
record the time
walking to check parts
I expect to find a place
to set up at second
check station.
It will help reduce time
walking back and forth
to check parts.
It took an average of
ten seconds longer to
check parts at the table
in between Hobs than
the table in middle of
line. We have enough
gages on line for both
sides of line.
Run-out is an hourly
check that is charted.
I learned that a table at
middle of line would be
better and that we have
enough gages on the line.
If I had to do this over
again, I would have tried
to find a table for the
center of line
In my next PDCA, I will
set a table up and start
working on finding the
most efficient place for
checking part quality.
TIME:
11:00 AM
“Go See” X
“Exploratory”
“Hypothesis”
DATE:
6-01-16
Set up a quality check
station at the head of
the line. Have each
operator run five
machines and collect
data.
We will record the
number of pieces
produced and how
many hob adjustments,
are needed for part
quality.
We will test this with 1
operator on second
shift and 2 operators
on first shift for two
hours
I expect to learn the
average parts that an
operator can run on five
machines and the
amount of time spent
making adjustmentsTIME:
11:00 AM
“Go See”
“Exploratory” X
“Hypothesis”

17. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
17
KATA PDCA CYCLES RECORD(each row = one experiment)
Date: 5-31-16 Process: Hob Machining of gears
Obstacle: We don’t know how the operators will cover work load
going from 3 shifts to 2 shifts
Process Metric: Save time checking pieces
Learner: Terry Coach: John
Date, Time, Type, Step & Metric What do you expect?
Coaching Cycle
Experiment
What happened?
(observe)
What did you learn?
(what you expected? / what happened?)
DATE:
5-31-16
Work with operators to
find the best place for
second check station
at end of line
To help reduce the
time for checking
pieces, and see if we
need more gages and
record the time
walking to check parts
I expect to find a place
to set up at second
check station.
It will help reduce time
walking back and forth
to check parts.
It took an average of
ten seconds longer to
check parts at the table
in between Hobs than
the table in middle of
line. We have enough
gages on line for both
sides of line.
Run-out is an hourly
check that is charted.
I learned that a table at
middle of line would be
better and that we have
enough gages on the line.
If I had to do this over
again, I would have tried
to find a table for the
center of line
In my next PDCA, I will
set a table up and start
working on finding the
most efficient place for
checking part quality.
TIME:
11:00 AM
“Go See” X
“Exploratory”
“Hypothesis”
DATE:
6-01-16
Set up a quality check
station at the head of
the line. Have each
operator run five
machines and collect
data.
We will record the
number of pieces
produced and how
many hob adjustments,
are needed for part
quality.
We will test this with 1
operator on second
shift and 2 operators
on first shift for two
hours
I expect to learn the
avg parts that an
operator can run on 5
machines and the
amount of time spent
making adjustments. I
am unsure if we can
produce 500 quality
parts over a 2 hour
period, which is what is
necessary to cover the
customer demand for
production
I expect Charles on 1st
shift will produce more
parts than James on 2nd
shift due to training
Jennifer, new operator
The operator averaged
413 over two hours.
Charles produced 350
James produced 583
Jennifer produced 308
(in training).
So, James on 2nd shift
actually produced more
that Charles on first
shift, even though he
was training Jennifer as
well as running his own
production
requirements. This was
an unexpected surprise.
It was reported that it is
possible to run over 500
parts in two hours.
I will talk with James to
see if he ran any
differently than Charles
or Jennifer.
When all machines are
available to run I don’t
believe it will be a
problem to reach desired
number of 500 quality
parts produced over a
two hour period. We
should be able to revise
the standard work to
match James’ best
practice.
TIME:
11:00 AM
“Go See”
“Exploratory” X
“Hypothesis”

18. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
18
KATA PDCA CYCLES RECORD(each row = one experiment)
Date: 6-02-16 Process: Hob Machining of gears
Obstacle: We don’t know how the operators will cover work load
going from 3 shifts to 2 shifts
Process Metric: Shared labor Hob/shape
Learner: Terry Coach: John
Date, Time, Type, Step & Metric What do you expect?
Coaching Cycle
Experiment
What happened?
(observe)
DATE:
6-02-16
Have the first operator
work at four of the Hob
machines for 2.5 hours
of the shift and a
second operator run
six Hob machines for 8
hour shift.
The first operator will
then move to Shaper
cell for the remainder
of shift
I expect to run between
400-500 parts at the
Hob the first 2.5 hours
and 500 to 600 pieces
at the six shapers for
the remainder of shift
It should increase
output at audit. This
will help our
productivity measure of
Parts Per Labor hour
(PPLH)
TIME:
2:00
“Go See”
“Exploratory” X
“Hypothesis”
DATE:
TIME:
“Go See”
“Exploratory”
“Hypothesis”

19. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
19
KATA PDCA CYCLES RECORD(each row = one experiment)
Date: 6-02-16 Process: Hob Machining of gears
Obstacle: We don’t know how the operators will cover work load
going from 3 shifts to 2 shifts
Process Metric: Shared labor Hob/shape
Learner: Terry Coach: John
Date, Time, Type, Step & Metric What do you expect?
Coaching Cycle
Experiment
What happened?
(observe)
What did you learn?
(what you expected? / what happened?)
DATE:
6-02-16
Have the first operator
work at four of the Hob
machines for 2.5 hours
of the shift and a
second operator run
six Hob machines for 8
hour shift.
The first operator will
then move to Shaper
cell for the remainder
of shift
I expect to run between
400-500 parts at the
Hob the first 2.5 hours
and 500 to 600 pieces
at the six shapers for
the remainder of shift
It should increase
output at audit. This
will help our
productivity measure of
Parts Per Labor hour
(PPLH)
Operator 1 ran 380
parts at the Hobs for
the first 2.5 hours
running six Hob
machines
He ran 394 at the
Shaper machine in 5
hours running 4 shaper
machines
I learned that reaching
500 at Hobs in 2.5 hours
is possible. The operator
is a new employee (less
than 90 days) and should
get faster with more
time, training and
experience.
If six Shaper machines
are running getting 600 in
5.5 hours, then it should
be easy for the
Shaper machines to
average 20 parts per hour
per machine
TIME:
2:00
“Go See”
“Exploratory” X
“Hypothesis”
DATE:
6-03-16
I plan to have 1
operator on first shift
run a layout of 6 Hobs
inline with check
station at both ends of
the line. I will
compare this to a
layout of 6 Hobs in a U-
shape cell to see if this
is an advantage to
running with the U-
shaped cell layout and
the two check
stations.
I expect there will not
be a advantage running
U-shaped for six hours a
day after time spent
adjusting machines and
quality checking the
first pieces.
TIME:
11:00
“Go See”
“Exploratory” X
“Hypothesis”

20. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
20
KATA PDCA CYCLES RECORD(each row = one experiment)
Date: 6-02-16 Process: Hob Machining of gears
Obstacle: We don’t know how the operators will cover work load
going from 3 shifts to 2 shifts
Process Metric: Shared labor Hob/shape
Learner: Terry Coach: John
Date, Time, Type, Step & Metric What do you expect?
Coaching Cycle
Experiment
What happened?
(observe)
What did you learn?
(what you expected? / what happened?)
DATE:
6-02-16
Have the first operator
work at four of the Hob
machines for 2.5 hours
of the shift and a
second operator run
six Hob machines for 8
hour shift.
The first operator will
then move to Shaper
cell for the remainder
of shift
I expect to run between
400-500 parts at the
Hob the first 2.5 hours
and 500 to 600 pieces
at the six shapers for
the remainder of shift
It should boost output
at audit. This will help
our productivity
measure of Parts Per
Labor hour (PPLH)
Operator 1 ran 380
parts at the Hobs for
the first 2.5 hours
running six Hob
machines
He ran 394 at the
Shaper machine in 5
hours running 4 shaper
machines
I learned that reaching
500 at Hobs in 2.5 hours
is possible. The operator
is a new employee (less
than 90 days) and should
get faster with more
time, training and
experience.
If six Shaper machines
are running getting 600 in
5.5 hours, then it should
be easy for the
Shaper machines to
average 20 parts per hour
per machine
TIME:
2:00
“Go See”
“Exploratory” X
“Hypothesis”
DATE:
6-03-16
I plan to have 1
operator on first shift
run a layout of 6 Hobs
inline with check
station at both ends of
the line. I will
compare this to a
layout of 6 Hobs in a U-
shape cell to see if this
is an advantage to
running with the U-
shaped cell layout and
the two check
stations.
I expect there will not
be an advantage
running U-shaped for six
hours a day after time
spent adjusting
machines and quality
checking the first
pieces.
The operator ran 1344
parts with the Hob
machine running inline.
The operator produced
1837 running in a U-
shaped cell. Operator said
that he must cold start
every machine now that
there isn’t a third shift.
Running warm up cycles
and one piece load to
check size and make
adjustment. He ran 84 for
his first hour. He also had
machine down waiting for
Hob to be sharpened
He ran machines in
another line.
I learned that the U-
shaped cell layout
produced over 500
additional parts.
However, we are losing
production because of
cold start up with no
parts in que as we had
running 3 shifts. I
learned that running the
machines in straight line
didn’t produce as many
parts as the U-shaped
cell on first shift.
TIME:
11:00
“Go See”
“Exploratory” X
“Hypothesis”

21. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
21
KATA PDCA CYCLES RECORD(each row = one experiment)
Date: 6-6-16 Process: Hob machining of gears
Obstacle: We don’t know how the operators will cover work load
going from 3 shifts to 2 shifts
Process Metric: Straight line verses U-shaped cell
Learner: Terry Coach: John
Date, Time, Type, Step & Metric What do you expect?
Coaching Cycle
Experiment
What happened?
(observe)
What did you learn?
(what you expected? / what happened?)
DATE:
6-6-16
I plan to have an
operator on second
shift run a straight
inline layout of the 6
Hobs with check
station at both ends of
Hob line. We will leave
al parts in que from
first shift.
I want to see how
many parts are gained
in comparison to the
cold starting without
parts in que. There
should not be the down
time waiting on the
first piece at
packaging
I expect that the inline
layout without the delay
from the cold startup
will produce the same
production output
numbers. I expect this
will be closer to the
same production as
running the U-shaped
cell.
TIME:
11:00
“Go See” X
“Exploratory”
“Hypothesis”
DATE:
TIME:
“Go See”
“Exploratory”
“Hypothesis”

22. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
22
1
2
3
4
We have 1,000 pcs in inventory at the start of the line; all other machines produce in flow
We check quality according to a sampling plaan of 6 parts every 15 minutes.
We 100% final audit per customer contract requirements at pack.
BLOCK DIAGRAM
OBSERVATIONS
1,000 pcs
Due to diminishing production volume we have exess capacity in our Hob Machines and Turning Mills.
CONDITIONCURRENT
HOB1 HOB2 HOB 3 HOB4 HOB5 HOB6 HOB7 HOB8 HOB9
HOB10 HOB11 HOB12 HOB13 HOB14 HOB15 HOB16 HOB17 HOB18
Shaper 1
Shaper 2
Shaper 3
Shaper 4
Shaper 5
Shaper 6
CNC
Machine 1
CNC
Machine 2
Turning
Mill 1
Turning
Mill 2
Turning
Mill 3
Turning
Mill 4
Final
Audit
and
PAck
I
QA
Turning
Mill 5
Turning
Mill 7
Turning
Mill 6
Turning
Mill 8

23. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
23
1
2
3
4
1,000 pcs
BLOCK DIAGRAM
OBSERVATIONS
CONDITIONTARGET
HOB1 HOB2 HOB3 HOB4 HOB5
HOB6 HOB7 HOB8 HOB9 HOB10
Shaper 1
Shaper 2
Shaper 3
Shaper 4
Shaper 5
Shaper 6
CNC
Machine 1
CNC
Machine 2
Turning
Mill 1
Turning
Mill 2
Turning
Mill 3
Turning
Mill 4
Final
Audit
and
PAck
I
QA

24. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
24
F/A - Pack
Mill 8
Mill 7
Mill 6
Mill 5
Mill 4
Mill 3
Mill 2
Mill 1
CNC 2
CNC 1
Shaper 6
Shaper 5
Shaper 4
Shaper 3
Shaper 2
Shaper 1
Hob 18
Hob 17
Hob 16
Hob 15
Hob 14
Hob 13
Hob 12
Hob 11
Hob 10
Hob 9
Hob 8
Hob 7
Hob 6
Hob 5
Hob 4
Hob 3
Hob 2
Hob 1
Hob 0
Hob 1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHER PROCESS METRICS:
Mill Reliability is 80%
Overtime is due to machine reliability at Turning Mills 1,7, & 8
NOTES AND OBSERVATIONS
PROCESS CHARACTERISTICS:
We have excess capacity and high variation in machine cycle
with our Hob Machines. Hob 18 cycle time exceeds Takt Time
We have excess capacity and high variation in machine cycle
with our Turning Mill Machines.
PPLH = 27.5
Scrap = 6.7%
OverTime = 8%
First Pass Yield = 93%
Exit Cycle Var(Pack) = 10 s +/- 12%
Hob 18 Lowest Repeatable Hi Var = +195%
Lo Var = - 24%= 14 seconds
Takt Time = 12.3 seconds
Planned Cycle Time= 10.5 Seconds
Number of Shifts = 3
Number of Operators = 10
CURRENT CONDITION SUMMARY SHEET
Outcome Metrics (See Charts)
Process Stability:

25. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
25
F/A - Pack
Mill 4
Mill 3
Mill 2
Mill 1
CNC 2
CNC 1
Shaper 6
Shaper 5
Shaper 4
Shaper 3
Shaper 2
Shaper 1
Hob 10
Hob 9
Hob 8
Hob 7
Hob 6
Hob 5
Hob 4
Hob 3
Hob 2
Hob 1
Hob 0
Hob 1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
Outcome Metrics (See Charts)
Process Stability:
Mill Reliability is 90%
TARGET CONDITION SUMMARY SHEET
Machine cycle and capacity is balanced awith 10 Hobs
None of the Hob cycle times exceed Takt Time
Machine cycle and capacity is balanced awith 4 Turning Mills
Number of Operators = 10
Number of Shifts = 3
OverTime = 10%
Planned Cycle Time= 10.5 Seconds
NOTES AND OBSERVATIONS
PROCESS CHARACTERISTICS:
OTHER PROCESS METRICS:
Takt Time = 12.3 seconds
Hob Lowest Repeatable
= 10 seconds
Exit Cycle Var(Pack) = 10 s +/- 10%
Hi Var = +15%
Lo Var = - 15%
First Pass Yield = 96%
PPLH = 37.5
Scrap = 5.0%

26. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
26

27. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
27

28. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
28

29. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
29

30. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
30

31. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
31

32. KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
32
KATA PDCA CYCLES RECORD(each row = one experiment)
Date: Process:
Obstacle: Process Metric:
Learner: Coach:
Date, Time, Type, Step & Metric What do you expect?
Coaching Cycle
Experiment
What happened (observe
closely)?
What did you learn?
(what you expected? / what happened?)
DATE:
TIME:
“Go See”
“Exploratory”
“Hypothesis”
DATE:
TIME:
“Go See”
“Exploratory”
“Hypothesis”
SPECIFIC DETAILS OF THE
STEP
SPECIFIC DETAILS OF HOW
IT WILL BE MEASURED
DOES THIS STEP BUILD
FROM THE PREVIOUS
PDCA?
MAKE A PREDICTION
IF INTRODUCING A
CHANGE, WHAT IMPACT
WILL IT HAVE ON
METRICS?
FACTS AND DATA HERE
ABOUT THE PROCESS?
ABOUT SCIENTIFIC PROBLEM
SOLVING?
IF YOU WERE DOING THIS
PDCA AGAIN, WHAT WOULD
YOU DO DIFFERENTLY?
HOW WILL THIS IMPACT
YOUR NEXT PDCA?
SPECIFIC DETAILS OF THE
STEP
SPECIFIC DETAILS OF HOW
IT WILL BE MEASURED
DOES THIS STEP BUILD
FROM THE PREVIOUS
PDCA?
MAKE A PREDICTION
IF INTRODUCING A
CHANGE, WHAT IMPACT
WILL IT HAVE ON
METRICS?
FACTS AND DATA HERE
ABOUT THE PROCESS?
ABOUT SCIENTIFIC PROBLEM
SOLVING?
IF YOU WERE DOING THIS
PDCA AGAIN, WHAT WOULD
YOU DO DIFFERENTLY?
HOW WILL THIS IMPACT
YOUR NEXT PDCA?