Implementation
Implementing
TWI as an Integral Part of Lean
According
to Art Smalley, author of the article Basic Stability is Basic to
Lean Manufacturing Success, certain pre-conditions are needed for
a lean implementation to proceed smoothly that include having relatively
few problems in equipment uptime, available materials with few defects,
and strong supervision at the production line level. Taachi Ohno
advised companies to "start from your greatest point of need"
when going down this path, and according to Art Smalley, the greatest
point of need at Toyota is attaining basic stability that starts
with a well trained workforce.
Basic stability
implies that without fundamental items like machine uptime or human
resources in place you cannot run a production line. Therefore,
before going too far down the road with the lean elements of flow
and tact time, you must first determine whether you have a consistent
and predictable process by asking:
.
1. Do you have trained employees available to handle
the current processes?
2. Do you have work methods, such as basic work instructions, defined
or standards in place?
If the
answer to both of these questions is no, you do not have a consistent
and predictable process needed to improve. You need Training Within
Industry (TWI).
PLAN
Identify problems that can be solved
with TWI training to improve the overall performance of the organization.
Introduce JR to create a positive work environment and JI to provide
your people with a proven methodology for them to use to stabilize
processes as the first step to standardize work. Identify a place
to start. Identify the people who must be trained, when and in what
jobs in order for them to eliminate variation in how work is performed
within this process
DO
Introduce the JR and JI programs
the same week to a class of ten (10) participants. The mix of people
should include the company trainer candidates, team leaders, "informal
floor leaders", operators, support staff, and union representation.
Key people can observe the training at no additional cost to become
familiar with the programs they are being asked to support to assure
a successful implementation.
Form a cross-functional team from this group and
challenge them to apply what they learned in class to document the
current best way to do jobs within a pilot project where the impact
of JI can be measured. As the team reaches consensus on what the
current best way jobs are to be performed, use the JI Job Breakdowns
to retrain operators while developing JI Breakdowns for upstream
jobs within the process. Audit these jobs to make sure people continue
to do jobs as trained to assure improvements are sustained. Encourage
people along the way to use JR to resolve culture and operational
issues that arise to break down barriers to change. Evaluate what
you learned in the pilot before moving on to the next process that
will provide a basis to create a plant roll-out plan that may involve
training company trainers to internalize the training
CHECK
Establish measures like the ones
below and compare results to evaluate the impact of TWI:
- Reduced training time
- Increased production
- Fewer accidents
- Less scrap
- Less rework
- Less tool and equipment damage
- Increased job satisfaction
- Improved quality
- Increased profits
ACT
Contract with the TWI Institute to
have a certified trainer deliver the 10-hour programs of JI and
JR for a class of 10 people selected to participate in the initial
TWI pilot project. The trainer will coach the participants and other
company personnel between classes on how best to apply what was
learned in class so the pilot can get off to fast start to get the
company down the path to standard work.
COST
$12,000 plus travel and expenses. An additional fee of $1,000
is added to the cost to compensate the trainer for travel time
beyond North America.
TRAINING COMPANY TRAINERS
Companies with more than 120 +- employees and/or
multiple locations will minimize the cost to roll out TWI by having
the TWI Institute train company trainer(s) after the initial delivery
of the 10-hour JR, JI, JM and Job Safety programs.
- The TWI Institute Trainer Program is made up
of four (4) separate 40 hour train-the-trainer programs, one for
each module of JR, JI, JM and JS.
- TWI Institute regularly schedules open enrollment
training in San Diego, CA, in Syracuse, NY and also at host companies
located anywhere in the US.
- Training is conducted on site for organizations
globally for a class of six (6) trainers.
TWI Institute will also conduct trainer classes in English at
companies located outside of the US for a class of six (6) trainers.
- A travel stipend may be added to the cost to
compensate the master trainer when extended travel times are involved
- Observers are NOT permitted to attend these sessions.
COST:
$4,500 for each 40-hour training program plus trainer materials:
JR & JS - $300: JI - $400; JM - $800. Each kit includes trainer
delivery manuals and materials, demonstration kit for JI and JM
only, and all supplies needed for one class of 10 participants.
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