Teach Lean Six Sigma the Karate Way

After teaching martial arts for over 40 years, I’ve found that karate to be effective and useful in training Lean and Six Sigma. 

I have to admit, I’ve taught martial arts longer than LSS, but when I do sit down with students in a classroom situation, the sensei comes out of me, not as tough as finger-tip or knuckle pushups, but disciplined enough.

As I’ve met individuals who sat for a weekend or for four straight weekday classes, take test, walk away with impressive certificates, I’ve had, on many occasions, realized that these LSS student have no idea on what they’ve learned much less implement their new found knowledge. Intellectually, they’ve satisfied an important part of learning but not the skill to affect change where, sooner than later, they’ve simply abandoned the training.

Through personal experience, I’ve recognized the similarities between Martial Arts and Lean Six Sigma and determined that I can use both what I know to develop and deliver an effective training program.

In karate, a student or kohai, undergoes three phases of learning, those being “kihon”, “kata”, and “kumite”.

But, before I tread further, I’d like to introduce Neil Burch and his four-phase learning concept consisting of: 

• Unconscious Incompetence,

• Conscious Incompetence, 

• Conscious Competence, and 

• Unconscious Competence.

We’ve all gone through it, learned something new, the awkwardness but yet excitement of, first time, stepping into a dance floor, bowling lane, golf course, or swimming pool, kind of knowing what to expect but not really until committing, the key word: “commit”.

Let’s use for example a new student who has never taken karate before. Aside from watching movies showing acrobatic, body contortionist maneuvers, bad guys sent flying through windows and the muscular and handsome hero saving the world or universe, the “newbie” has no idea what it takes to be that person. Therefore, that person is considered unconscious incompetent because he or she doesn’t know what martial arts is all about and definitely not competent in performing or executing even the basic of movements.  

So the next step, is for that student to build up the courage to step into a class, or “dojo”, put on a cotton robe with a white belt wrapped around him or her, bow to everyone, and listen, learn, and do without question what individual (“sensei”) in front of the class, wearing the same white robe but instead with the black belt wrapped around him displaying knuckles heavily calloused from years of pounding cement. 

After months of training in front of the tutelage of the sensei, the student slowly learns to be calm as good, however, with certain moves not yet established or mastered. In this phase the student is conscious about his body placement, but still incompetent.

Now, should the student continue to train for over a year, he becomes better and almost as good as a sensei, but as good as a black belt instructor. This phase is called conscious competence.

When the student is able to obtain a black belt and uses his techniques in a life-and-death situation without thinking, then this phase is called unconscious competence where movements are executed without thought and second nature, kind of like eating dinner where you’d just sit down and eat not bothering with the intricate details of shoveling food in your mouth, chewing “x” amount of times before swallowing.

For learning purposes, these three terms (kihon, kata and kumite), like what’s used in Toyota Production Systems or Lean, are Japanese. Karate, though has roots deep from India, is also Japanese.

Kihon (KEY-hun) means basics. A kohai is taught to make a fist, stand, kick, block, punch, terminology, culture and history. Part of living the karate experience is to undergo years of standardization that has worked for the Japanese for thousands of years. The student’s goal is to look inward and perfect each movement as he executes them seeking continuous improvement with each and every technique. Repetition is the key. 

Kata (kah-TAH) means form. In karate, as well as in many martial arts schools, kata, like a dance or ritual, is a series is sequential steps and techniques taken from kihon that the student performs to increase skill, knowledge, understanding and competence. To achieve a black belt, the student must master about 20 forms that may include weapons. Kata mimics combat between the student and imaginary opponents. Kata conducted with other students is referred to as “bunkai.” Kata was developed to maintain, sharpen skills, focus, or internal intent needed for combat when and if called upon. Like kihon, repetition is important. The goal is to develop a warrior mindset or intent or “tamashii”!

Students who master kata, would be considered accomplishing the conscious competent phase.

Kata is used extensively in lean manufacturing where the managers go over routines, perform standardize work, and reflect intention of continuous improvement.      

The next phase is kumite (KOO-meh-tay). This is where you put your techniques and training together against another opponent or opponents through sparring. Before a student is allowed to free spar, he must be adept in regimental one-step routines called “wazas” or kihon-ippoon kumite, which like kata are pre-arranged and specific, where one attacks with one technique and the other defends. This is repeated many times executing various attack strikes, punches and kicks, with the other defending appropriately. The theory is that if a student is a expert in wazas and ippon kumite, he would be able to graduate to “jiyu kumite” or free sparring.

Dojo or school sparring is not without its share of consequences. Despite the careful watch of an instructor, it is common for students to get injured during kumite, but, many agree, it is better to get hurt in the dojo than out in the street

There is an assumption that when someone takes karate, that it will be used in self-defense or combat fighting. Someone who has learned only kihon or kata may not be prepared to defend himself unless he has had past experience in sports like wrestling or boxing or, worse, getting into fights as a kid with siblings or in school. 

To be able to use karate without thinking is to achieve the unconscious competent phase.

What I’ve done here, is paint the picture of an intricate and complex situation, bringing to fold the concepts of lean manufacturing and six sigma. You can learn intellectually the concepts by reading, taking classes, and having conversations, discussions or arguments, but to execute the right methods and techniques, at the right time and place, is the question; as what you, ultimately, do can reverse planned outcomes, regardless of what you know, if done incorrectly.

In order to face an opponent head on in kumite, you must be adequately prepared. While you may have a certificate proving you endured classroom education, executing lean manufacturing and six sigma techniques could end up with less than desired results.  

It is necessary to get into a ring and feel the smack of a round house kick or left hook to the head before truly understanding the value of what you learned.

And with that said, after hanging that certificate on the wall, be sure you have a sensei nearby to mentor you, so that your newly learned knowledge becomes something useful to you and the company you work for.

Hai, wakirimaska?