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Solutions Through People

Lean Training and Programming

What is Lean Training?

Lean training helps workers build a foundation for unified, repeatable success.

As a workplace methodology, Lean describes how an organization operates. The primary goals of Lean include reducing waste and streamlining processes, but the overall objective is to create an organizational mindset where continuous improvement thinking is unified and workplace behaviors are universal and standardized.

Lean’s never-ending cycle of waste removal and value identification can achieve the following:

  • Increased production
  • Decreased downtime
  • Improved products and services
  • Elimination of defects in processes and products
  • Streamlined inventory
  • Optimization of your workforce’s skills
  • Workers empowered to identify areas for improvement

Lean foundational programs like Job Instruction, Job Relations, Kata Practice, Standardized Work and TWI Problem Solving can be tailored to employees at different levels within different industries, including frontline workers, middle-management or senior executives in manufacturing, healthcare and beyond.

When combined with Six Sigma (the statistical approach to quality control), Lean trainees can earn certifications (or belts) for achieving subsequent levels of mastery. However, while Six Sigma belts and official Lean certifications certainly have their place, our ultimate goal is to provide iterative, lasting, practical knowledge and skills  that can be applied in any professional setting.

The work we do with you and your teams is designed to be an ideal foundation or complement to your current or planned training initiatives. These can include Lean manufacturing/healthcare, continuous improvement, kaizen, operational excellence or talent development.

Results that make a difference

45

%
increase in productivity

25

%
reduction in waste

101

%
increase in improvement ideas

50

%
reduction in downtime

31

%
improvement in employee engagement
These statistics represent documented composite results from actual improvements measured in client engagements and tracking metrics from the U.S. government.

Programs for Lean

Our Lean manufacturing and healthcare training programs make a big difference for a simple reason — they are foundational. The end goal of each is to educate your workforce, train your leaders and improve processes in a way that will have a lasting positive impact.

Lean-related problems solved by our coaching and training programs.

Stalled Improvement Initiatives

Providing an improvement foundation; recognizing problems and root causes; achieving buy-in across the organizational spectrum

Lack of Engagement

Involving supervisors, teams and workers in ideation and solutions

Resistance to Collaboration

Creating alignment with your Lean vision; building productive relationships and teamwork between supervisors and workers

Skills Gaps

Identifying gaps; upskilling, reskilling and cross skilling

Instability

Developing the baselines for improvement: standards and Standardized Work

Physical and Personal Safety

Training workers and teams to be mindful, observant and responsive to risks and safety improvements.

What The Experts Say

Lean without TWI is like a saw without teeth.
Dwayne Butcher, former Vice President and Lean Architect From Lean Frontiers
Dwayne Butcher, Lean Frontiers, Saw without Teeth (Lean Training Page)
Employees feel the (TWI Institute Training Program) gives them a better opportunity to get to know new employees on a personal and professional level. ... Statistically, we went from a 6- to 8-month training curve down to 6 to 8 weeks. This is a huge improvement and it shows in the attitudes of new employees and their knowledge of the job at hand.
Al Engstrom, Plant Manager From Giants Foods
Al Engstrom, Plant Manager, Giants Foods (Job Instruction, Lean Training and Industries page)
We're a manufacturing company, but people are the core of our operation. TWI Institute's JR (Job Relations) program brought an emphasis on trust and transparency that built a foundation for a more collaborative and cooperative culture.
Norton McMurray
Andrea Lee, Norton McMurray (Job Instruction, Solutions and Lean Training Page)

Our Experience Offers You Insights to Improvement

Lean is not a quick fix for specific problems or challenges. Rather, it is a foundational business strategy that helps companies manage change, competitive advantage and customer value, while building in a framework for ongoing organization-wide improvement.

The TWI Institute brings you insights and experience from markets and marketplaces worldwide. This track record helps global players – and locals who play globally – leverage the power of people to ignite ideas, solve problems and spur growth.

Our end-to-end approach sets us apart

Our proven methods stretch far beyond essential TWI, Kata and Standardized Work training. From initial preparation to ongoing consulting, we prepare people and workplaces for continuous improvement, better outcomes and increased engagement.
  1. 1
    Preparation
  2. 2
    Education
  3. 3
    Adoption
  4. 4
    Integration
  5. 5
    Certification
  6. 6
    Continuation
Step One:
Preparation

We start with an assessment and provide tailored recommendations for your workers and your workplace. KPIs are set, a communication strategy is planned and workforce orientation begins.

Step Two:
Education

Supervisors, team leaders and those who direct the work of others attend, participate and learn in our cornerstone programs: TWI, Kata and Standardized Work.

Step Three:
Adoption

We work with you to plan a pilot program and teams begin to learn by doing. Through workplace practice and coaching, we help students accept the ideas and put them to work. We’re with you through every step of the journey.

Step Four:
Integration

We assess learning, validate pilot results, incorporate skills into routines, evaluate practices and culture, and measure performance against KPIs.

Step Five:
Certification

We execute worker and workplace certifications, including TWI Certification (student and trainer), Kata Certification (student and trainer) Train-the-Trainer Certification, and TWI:2018 Certification.

Step Six:
Continuation

We stay connected with planned reassessments, KPI checks, remedial coaching, and re-certifications to protect and grow your return on investment.

Ready to get started?