Transcript Slide 1

Training Within Industry (TWI)
Superfactory Manufacturing Excellence Series
Lean Overview
5S & Visual Factory
Cellular Manufacturing
Jidoka
Kaizen
Poka Yoke & Mistake Proofing
Quick Changeover & SMED
Production Preparation Process (3P)
Pull Manufacturing & Just In Time
Standard Work
Theory of Constraints
Total Productive Maintenance
Training Within Industry (TWI)
Value Streams
Contents
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Introduction
Background and History
Components and Implementation
Knowledge Check
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Introduction
• TWI provides a systematic approach to sustain changes
and continuously improve by
– Indoctrinating people into an “improvement” frame of
mind.
– Teaching people how to identify opportunities for
improving their jobs.
– Training people how to generate ideas to take advantage
of these opportunities.
– Showing people how to get these ideas into practice
right away.
– Creating ownership for people to maintain standard
work.
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Introduction
• The program is one of utter simplicity
• It uses a blueprinted procedure that requires a
minimum of time
• Adheres to the learn by doing principle
• Built in multipliers to spread the training
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Components and Implementation
• The Problem of Sustainability
• Components of TWI
– Job Instruction (JI)
– Job Methods (JM)
– Job Relations (JR)
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The Problem of Sustainability
Output
Event #3
What Standard should be
Event #2
Maintenance
What Standard should be
Event #1
Maintenance
Work Standard
What actually becomes
the Standard when people
do not sustain the changes.
Time
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Components of Training Within Industry
• Job Instruction Training (JI)
– teaches supervisors how to quickly train employees to
do a job correctly, safely, and conscientiously.
• Job Methods Training (JM)
– teaches supervisors how to continuously improve the
way jobs are done.
• Job Relations Training (JR)
– teaches supervisors how to develop and maintain
positive employee relations to prevent problems from
happening and how to effectively resolve conflicts that
arise.
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JI: Four Steps
1. Prepare the worker to learn
2. Present the operation
3. Try-out performance
4. Follow-up
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TWI: Common Procedures
• A common thread runs through all TWI programs as the
result of much trial and error learning during introduction:
– Each program has a similar 4-Step Method.
– The method is stated in shop terms, not in academic
language.
– Each participant must use the method to solve a current
problem in class to get immediate use and acceptance.
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TWI: Common Procedures
• Small groups of 10 to practice the method under
guided assistance to “learn by doing”.
• An outline of what and how and time sets a
universal standard.
• Ten hours of class are best delivered in five 2-hour
meetings without a break.
• Compact scheduling of the 5 meetings to keep the
subject fresh and not keep people away from their
jobs over long periods of time.
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