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 • Introduction • Background and History • Components and Implementation • Knowledge Check © 2007 Superfactory™. All Rights Reserved.
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. © 2007 Superfactory™. All Rights Reserved.
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 © 2007 Superfactory™. All Rights Reserved.
Components and Implementation • The Problem of Sustainability • Components of TWI • Job Instruction (JI) • Job Methods (JM) • Job Relations (JR) © 2007 Superfactory™. All Rights Reserved.
The Problem of Sustainability Output Event #3 What Standard should be Event #2 Maintenance What Standard should be Event #1 Maintenance What actually becomes the Standard when people do not sustain the changes. Work Standard Time © 2007 Superfactory™. All Rights Reserved.
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. © 2007 Superfactory™. All Rights Reserved.
JI: Four Steps Prepare the worker to learn Present the operation Try-out performance Follow-up © 2007 Superfactory™. All Rights Reserved.
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. © 2007 Superfactory™. All Rights Reserved.
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. © 2007 Superfactory™. All Rights Reserved.