Facilitator guide
Case objectives, demonstration plans, debriefs, common mistakes and application checks across all 81 workplace cases and method lessons.
Download Facilitator guide PDF · 166 pages · 65.1 MBLeadership and daily learning
Understand how the methods relate before selecting a detailed lesson.. Follow the visual, practise a decision, then check your thinking.
Fictional teaching examples and AI-generated illustrations. Proposed changes and goals are not achieved results. Use the written instructions and check local conditions before applying a method.
Turn strategy into daily learning
Direction becomes useful through discussion of actual capability and resources. Catchball links organizational intent with local feasibility rather than cascading unsupported targets. A daily board then exposes the gap between the agreed plan and observed work. Leaders go to the work, ask what is understood and remove obstacles while developing the team’s problem-solving ability. A small experiment records its prediction and observed result. Job instruction supports the competence required to execute safely and consistently. Review checks evidence of effect, not merely completed actions or attendance, and carries learning back to both local targets and the wider plan.
Follow the method
- Shared direction: Customer purpose and meaningful challenge
- Catchball: Test feasibility, resources and ownership
- Local target: Describe the next observable condition
- Daily evidence: Plan versus actual and abnormality
- Leader response: Go see, ask and remove obstacles
- Team experiment: Prediction, small test and observation
- Capability building: Teach key points and reasons
- Review and adjust: Verify outcomes; adapt the plan
Read the example carefully
Daily management supports response and learning; a board alone is not the system.
Catchball includes feasibility and horizontal resource conflicts.
A completed action is not proof of an improved or sustained result.
Try it before revealing the answer
A board lists all actions complete, but no later condition check exists. What should the leader ask next?
Reveal the answer and reasoning
Ask what changed in the work, where it was observed and when it will be checked again. Keep effectiveness pending until evidence is available.
Align direction through catchball
Catchball is a dialogue about purpose, contribution and feasibility. Begin with current evidence, then propose how a local team can contribute. Make resource needs and cross-team dependencies visible; the same specialist cannot be promised to incompatible work at the same time. Agree a bounded experiment or commitment with an owner, prediction and review point. Observe the result and its effect on workload and neighboring processes. Bring that learning back to both local plans and wider direction. The system depends on honest negotiation and learning; a cascade of targets without discussion does not provide the same mechanism.
Follow the method
- Purpose and challenge: Why this matters to customers
- Current condition: Evidence of capability and gaps
- Proposed contribution: Local result and supporting work
- Catchball conversation: Question assumptions and resources
- Horizontal alignment: Resolve shared capacity and dependencies
- Agreed experiment: Owner, prediction and review point
- Observed result: Outcome, workload and side effects
- Adjust the plan: Return learning to local and wider direction
Read the example carefully
Catchball is two-way discussion, including horizontal dependencies.
A proposed target is not an achieved outcome.
A shared resource needs an explicit feasible allocation.
Try it before revealing the answer
Two teams each promise daily support from the same specialist, whose capacity allows only one team per day. What should the catchball conversation produce?
Reveal the answer and reasoning
Expose the conflict and agree priorities, timing, scope or another feasible support arrangement. Record the resulting commitment and review evidence; do not approve both promises merely to preserve the target cascade.
Observe, coach and build capability
Observe what actually happens and separate facts from interpretations. Ask the learner how the work is understood and what obstructs the next condition. Where uncertainty calls for learning, use a small experiment with a prediction and compare the observation with that prediction. Where the need is competence in an established job, use job instruction: prepare, present the important steps with key points and reasons, let the learner try and explain, then follow up. These are related but distinct routes. Leader standard work creates time and responsibility for this support. Attendance, a coaching conversation or a completed demonstration alone does not establish sustained competence.
Follow the method
- See the work: Observe facts without assigning blame
- Ask the learner: Understand current reasoning and obstacles
- Define next condition: One observable step toward the challenge
- Predict and test: Small experiment with expected evidence
- Compare and reflect: What happened; what was learned?
- Teach the job: Important steps, key points and reasons
- Try and explain: Learner demonstrates understanding
- Follow through: Check competence and later condition
Read the example carefully
Gemba observation does not justify conclusions about unseen events.
Coaching an experiment differs from teaching an established job.
Follow-up should verify understanding and performance, not attendance alone.
Try it before revealing the answer
A learner repeats a step correctly once but cannot explain the identity check. Is the instruction complete?
Reveal the answer and reasoning
Not yet. Revisit the key point and reason, let the learner explain and demonstrate the full method, then follow up under appropriate supervision until competence is evidenced.
Sources and further reading
- LEI: Hoshin Kanri ↗
Vertical/horizontal alignment, PDCA and capability development
Method reference; original OPEX scenario and diagram are synthetic teaching content, not source case results. - LEI: Daily Management and Hoshin Kanri ↗
Daily standards/abnormalities and strategic feedback; do not copy source diagram
Method reference; original OPEX scenario and diagram are synthetic teaching content, not source case results. - LEI: Leader Standard Work ↗
Gemba, reflection, andon response, accountability and mentoring
Method reference; original OPEX scenario and diagram are synthetic teaching content, not source case results. - LEI: Kata ↗
Challenge, current condition, target condition, experiments and coaching
Method reference; original OPEX scenario and diagram are synthetic teaching content, not source case results. - LEI: Training Within Industry ↗
Prepare, present, try out, follow up; steps/key points/reasons
Method reference; original OPEX scenario and diagram are synthetic teaching content, not source case results. - LEI: Standard Work for Lean Leaders ↗
Leaders observe work and coach capability rather than blame or take over
Method reference; original OPEX scenario and diagram are synthetic teaching content, not source case results.
Take the lesson into your team.
Read the lessons online or use these PDFs to prepare, practise and review with your team. No sign-in needed.
Learner workbook
Printable case worksheets, blank observation records and five calculation exercises; answers are separate.
Download Learner workbook PDF · 169 pages · 10.7 MBAnswer key and coaching notes
Reasoned sample responses, worked calculations and coaching guidance; fictional examples are clearly labelled.
Download Answer key and coaching notes PDF · 105 pages · 8.5 MBMethod and application reference
The native method mechanisms and worked applications for all 68 detailed lessons, in a separate bookmarked portrait reference.
Download Method and application reference PDF · 141 pages · 10.2 MBIllustrated systems atlas
Five illustrated system chapters: 15 Flare concept maps and 26 original workplace teaching cards, with links to all 81 supporting cases and method lessons.
Download Illustrated systems atlas PDF · 69 pages · 55.8 MBPractise the methods in this system.
- Show how direction, local evidence, coaching and follow-through reinforce each other.
- Turn an organizational challenge into feasible contributions and two-way learning.
- Connect direct observation, a learning conversation, deliberate practice and follow-through.
Gemba: observe work, ask, follow through
Primary teaching mechanism belongs to leadership and daily learning. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Leader standard work supports problem solvers
Primary teaching mechanism belongs to leadership and daily learning. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Daily board: measure, respond, learn
Primary teaching mechanism belongs to leadership and daily learning. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Hoshin: align strategy through catchball
Primary teaching mechanism belongs to leadership and daily learning. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Improvement and coaching kata
Primary teaching mechanism belongs to leadership and daily learning. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Job instruction: steps, key points and reasons
Primary teaching mechanism belongs to leadership and daily learning. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Make tomorrow ready
Primary teaching mechanism belongs to leadership and daily learning. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →TPS: people, quality and synchronized flow
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Muda, mura and muri reinforce each other
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Takt, cycle time and lead time are different
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Batch transfer versus one-piece flow
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Production and withdrawal kanban
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Office pull: capacity, blocked work and aging
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Heijunka mix and pitch release
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Connect processes: flow, bounded FIFO or supermarket
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Standardized work: sequence, takt and standard WIP
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Manual, walking and machine time
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Yamazumi: movable elements and constraints
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →SMED: externalize safely, verify first good output
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Replenishment stock: lead time and uncertainty
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →PFEP to point-of-use replenishment
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →TOC five focusing steps
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Find the constraint: evidence, not the biggest queue
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Drum-buffer-rope: schedule, protect, release
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Buffer management: priorities and recurring causes
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Throughput versus local utilization
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Critical chain: dependencies, resources and buffers
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Lean and TOC: complementary questions, distinct controls
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Shorten the handoffs
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Give the request a clear next step
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Keep the assembly line ready for the next frame
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →A clearer start for every cut order
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Make the welding bay ready to work
Primary teaching mechanism belongs to quality control and dependable evidence. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →5 Whys with evidence and alternative branches
Primary teaching mechanism belongs to problem solving and verified change. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Choose a problem-solving approach
Primary teaching mechanism belongs to problem solving and verified change. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →From broad complaint to a testable problem
Primary teaching mechanism belongs to problem solving and verified change. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Conflict cloud: challenge assumptions
Primary teaching mechanism belongs to problem solving and verified change. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Choose the quality tool for the question
Primary teaching mechanism belongs to problem solving and verified change. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Record defects without changing the denominator
Primary teaching mechanism belongs to problem solving and verified change. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Rank problems on one declared basis
Primary teaching mechanism belongs to problem solving and verified change. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →See the distribution without losing the sequence
Primary teaching mechanism belongs to problem solving and verified change. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Test a relationship without declaring a cause
Primary teaching mechanism belongs to problem solving and verified change. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Unmix the data before blaming a shift
Primary teaching mechanism belongs to problem solving and verified change. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Turn fishbone branches into testable hypotheses
Primary teaching mechanism belongs to problem solving and verified change. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Close an NCR with verified action against recurrence
Primary teaching mechanism belongs to problem solving and verified change. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Stop the recurring leak
Primary teaching mechanism belongs to problem solving and verified change. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Make referrals ready
Primary teaching mechanism belongs to problem solving and verified change. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Send the right shipment
Primary teaching mechanism belongs to problem solving and verified change. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Make the morning easier
Primary teaching mechanism belongs to problem solving and verified change. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Find it. Use it. Reset it.
Primary teaching mechanism belongs to equipment wellness and oee. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →A tool room ready for the next job
Primary teaching mechanism belongs to equipment wellness and oee. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Give the press area a clear reset
Primary teaching mechanism belongs to equipment wellness and oee. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →