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TWI
An Overview of Training Within Industry
Steven Grossman EdD Susan Janus
August 12, 2011
www.TWI-Institute.org www.massmep.org2
Introductions TWI LEAN
Today’s Journey
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Introductions
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TWIEst. 1940
Walter Dietz
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The real job had to
be done by industry, within industry.
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B-17
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We Did lt !
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Toyota Production
System
TWI found new life in Japan
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Definition:“A supervisor is anyone who is in charge of, or directs the work of others”
TWI Original Focus:
“Five Basic Needs of Supervisors”
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KNOWLEDGE SKILL
Work
Responsibilities
Instructing
ImprovingMethods
Leading
Safety
Five Basic Needs
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How to teach
a person to do a job
correctly,
safely,
and conscientiously
Job Instruction Training (JI)
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How to analyze jobs
to make the best use of the
people, machines, and
materials
currently available
Job Methods Training (JM)
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How to build positive
employee relations, increase
cooperation and motivation,
and effectively resolve
and prevent people
problems
Job Relations Training (JR)
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How to identify the
direct and indirect
causes of incidents and
injuries and
prevent them
from happening
Job Safety (JS)
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A Closer Look at Job Instructions (JI)
Using 4-Step Method
JobBreakdowns
TrainingTimetable
How To Instruct
How To Prepare
“If the worker hasn’t learned, the instructor hasn’t taught”
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How to Instruct
4-Step Method
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No. __________
JOB INSTRUCTION BREAKDOWN SHEETOperation: _________________________________________________
Parts: _____________________________________________________________
Tools & Materials: ______________________________________________
What How WhyREASONSKEY POINTSIMPORTANT STEPS
Job Breakdown
= Script
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TrainingTimetable
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Attract / Trainable
Develop / Able
Engage / Improving
Enroll / Committed
Engagement of Employees
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Standardized Work
TWI
STANDARDIZED WORK
CHART
PROCESS Cycle Time TAKT TimeSAFETY QUALITY IN PROCESS
Glost Kiln Operator Cycle 30-minutes 1-cycle / 90-
minutes
Element
Number
Description Work Time Walk
TimeWORK AREA LAYOUT
1 Walk to GK #3 Exit 1.0
2 Discharge Car from GK#3 5.0
3 Discharge Car from GK#4 5.0 1.2
4 Record GK#4 car numbers and
temps1.0 0.7
5 Charge GK#4 5.0 0.3
6 Charge GK#3 5.0 1.0
7 Record GK#3 car numbers and
temps1.0 0.6
8 Return to loading 0.6
Total (min): 22 5.4COMMENTS:
Safety: Use high temp gloves, pusher to move cars and be mindful for oily/slick surfaces
Quality: Inspect kiln cars and repair downed ware and refractory. Use care not to damage glaze of unfired ware
GK#4
GK#3
ENTRANCE
ENTRANCE
EXIT
EXIT
1, 8
2
3
4
5
6
7
Panel Board
Panel Board
Load Station
Load Station
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Standardized Work –
What to Do
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Job Instruction Training
Highly Skilled Associates
Best Method
Standardized Work
Analysis Tool
Baseline for
Continuous
Improvement
Job Redesign
Eliminate Waste
Focus: Daily Waste Elimination
Focus: Capability & Talent
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Sustain TWI JI & JR
Potential of
Underutilized
People
Sustainment and Daily Improvement
Time
New Standard
What the Standard becomes
Gradually Improve of the Standard, TWI JM
Improvement Event
Perfo
rmance / O
utp
ut
Next Improvement Event
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Results!TWI =
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JI: Setup Operator Training at Albany International Monofilament Plant
0
5
10
15
20
25
Q4 '06 Q1 '07 Q2 '07 Q3 '07 Q4 '07 Q1 '08 Q2 '08 Q3 '08 Q4 '08
Human Error
JIMentoring
Begins
JIIntroduced
Results!
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Results!
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0
50
100
150
200
250
Jan-0
6
Mar-
06
May-0
6
Jul-06
Sep-0
6
Nov-0
6
Jan-0
7
Mar-
07
May-0
7
Jul-07
Sep-0
7
Nov-0
7
Jan-0
8
Mar-
08
May-0
8
Jul-08
Sep-0
8
Nov-0
8
Jan-0
9
Mar-
09
May-0
9
Jul-09
Sep-0
9
# o
f S
ub
mis
sio
ns
JM: Proposal Submissions
Results!
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Falls and Falls w/Injury per 1000 Patient Days
Results!
0
0.5
1
1.5
2
2.5
3
3.5
4Ja
n 0
9
Feb 0
9
Mar
09
Apr
09
May 0
9
Jun 0
9
Jul 09
Aug 0
9
Sep 0
9
Oct
09
Nov 0
9
Overall Average Falls Per 1000
Overall Average Falls Per 1000 with Injury
TWI JIRounding Training
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Results!
Reduced
Turnover
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Results!
Reduced
Turnover
ReducedAccidents
ReducedComp
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Results!Reduced
Turnover
ReducedAccidents
ReducedComp
ReducedRework
ReducedScrap
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Results!
Reduced
Turnover
ReducedAccidents
ReducedComp
ReducedRework
ReducedScrap
ReducedSetup Time
ReducedTakt Time
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Results!
Reduced
Turnover
ReducedAccidents
ReducedComp
ReducedRework
ReducedScrap
ReducedSetup Time
ReducedTakt Time
ImprovedMorale
Improved Profits
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The TWI Workbook:
Essential Skills for
Supervisors
Shingo Research and
Professional
Publication Prize
2007
Implementing TWI:
Creating and
Managing a Skills
Based Culture
By Patrick Graupp
and Robert J. Wrona
QUESTIONS?
MassMEP: “Lean Management In the Fast Lane”
Pit Crew Challenge
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