Return On Investment (ROI)
Metrics
How do you measure the effectiveness
of your TWI implementation? How can you sell this to the management
team? What should you expect on each TWI module?
Absenteeism and
Employee Turnover:
Job Relations (JR) helps the supervisor or team
leader develop a professional, positive relationship with those
that report to them. The program will assist the supervisor in
making better decisions that will make better relationships. The
most effective metric for JR is employee absenteeism. An employee
who feels valued and is respected for their individual knowledge
and contributions tends to want to be at work. As Job Relations
training takes hold, the company should also see a reduction in
unscheduled absenteeism. This should then be able to be measured.
An additional measure would be employee turnover. Both of these
metrics indirectly affect the productivity and capacity metrics
which most organizations track.
Training Time, Rework, Operator
Error (PPM):
Job Instruction has a high impact on standard work
and training time. Implementation of this program will drive several
metrics including time to proficiency, and increased quality. The
additional benefit of minimizing rework is accomplished by having
the currently best known process utilized by all operators. Commonly
the root causes for many quality issues are defined as operator
errors. Training to a defined standard will allow the company to
drill beyond the typical problem and address process short comings
to further reduce ppm defects and simultaneously reduce rework.
Sustainability is the result of making the best currently known
method the standard and training all operators in the same way.
An indirect benefit will be seen on the productivity and capacity
metrics.
Productivity, Cost, Quality:
Job Methods impacts the most
traditional metrics. However, if you have not established a groundwork
with Job Relations and Job Instructions, the gains may not be long
term or consistent. Job Methods trains workers to evaluate every
detail and eliminate those that have no purpose, combine and rearrange
those that are still required, and simplify those that add value.
As a net result, the dramatic impact on productivity can be significant.
Elimination of 10-20% of detailed steps is typical on a first pass,
with more reductions to follow due to simplifying the remaining
processes. The impact the increased productivity has on cost is
amplified when processing materials are also eliminated. The final
benefit, improved quality, will easily be demonstrated in the reduction
of ppm defects.
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