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:

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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.

1. 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.
2. TWI Institute regularly schedules open enrollment training in San Diego, CA, in Syracuse, NY and also at host companies located anywhere in the US.
3. 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.
4. A travel stipend may be added to the cost to compensate the master trainer when extended travel times are involved
5. 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.