TWI – Training Within Industry

Jerry Thiltgen
Manager, Operational Excellence
[email protected]
 TWI in the 1940’s

MISSION:

“to help industry to help itself

to get out more materials
than ever been thought
possible, and at constantly
accelerating speed”
to:

WIN A GLOBAL WAR

 1940’s Mission “Accomplished”

There were over 1 million people trained in TWI

during the war effort working in about 600
companies:

• 86% Increased production by at least 25%

• 100% Reduced training time by 25% or more
• 88% Reduced labor hours by over 25%
• 55% Reduced scrap by at least 25%
• 100% Reduced grievances by more that 25%
 TWI Training Within Industry

• A 1940’s World War II effort, developed to help

industry feed the war effort.

• In the 1950’s, Used to rebuild the infrastructure of

Japan after the war.

• Today, The program has spread world wide (and

stood the test of time for over 70 years,) and is as
relevant today as then.
Today-We Compete Globally

Implementing Lean:
(Continuous Improvement)
(The easy part)

Sustaining Lean:
(Continuous Improvement)
(The hard part)
 Are today’s supervisors better
prepared?

According to a Gallup Poll:

80% of people leave their jobs because of their

immediate supervisor.
The average cost to replace them is
about 1.5 times their salary
(when you can find qualified replacements)
 15 Human Relations Issues that Impact Employee
Morale (survey of 25K people)

1. Showing employees appreciation for the work they’ve

done
2. Communicating information and directions
3. Listening to ideas and concerns
4. Treating all employees fairly
5. Treating everyone with dignity and respect
6. Being sensitive to personal problems
7. Handling corrective action in a tactful manner
8. Job security
15 Human Relations Issues that Impact Employee
Morale (survey of 25K people)

9. Good wages
10. Good fringe benefits
11. Opportunities for promotion and growth within the
organization
12. Good working conditions
13. Providing a safe work environment
14. Adequate job/technical training
15. Permitting participation in decision making
 It’s all about the people.

“In this age, I am painfully aware of the fact that people

tend to forget the need for training. Of course, if skills to
be learned are not creative or stimulating and if they do
not require the best people, training may not seem
worthwhile. But let’s take a hard look at the world.

No goal, regardless of how small, can be achieved

without adequate training.”
Taiichi Ohno,
Toyota Production System:
Beyond Large Scale Production, page 69.
 Supervisors have 5+ needs

Skill In
Leading Things
Knowledge of supervisors
Work need to do

Things Skill in
supervisors Safety Instructing
need to know

Knowledge of
Responsibilities Skill in Improving Methods
 Program Structure

• Each program has a four-step method

• Each program is structured in simple language
• Each program is structured for 3 hour sessions
over a 5 day period, typically conducted on-site to
minimize time away from work
• Class size is limited to a maximum of 12
• Each participant must demonstrate the skill by
using the method on real life issues during class
 Simple 4-Step Method

1. Preparation (Help the learner think to aid

comprehension of the new idea)
2. Presentation (Add the new idea to those already
in the learner’s mind)
3. Application (Train the learner to apply what
was presented and check results)
4. Testing (Test the ability of the learner to
apply the new idea alone)
* Developed by Charles R. Allen during WW2
Training Within Industries (TWI) provides:

a systematic approach to help sustain changes

and continuously improve by:
• Challenging people to identify opportunities to improve their
jobs.
• Training people how to generate ideas to take advantage of
these opportunities.
• Showing people how to get ideas into practice right away.
• Creating ownership for people to maintain standard work.
• Strengthening personal relationships
• Creating an environment that is safe and encouraging staff to
take on more responsibility for success.
• Multiplying results by passing on the skills
 Continuous Improvement Activities

Lean, TOC, Six Sigma,

etc.
$ (Continuous
Improvement) efforts
strive for this stair
step growth

Desired
Slope

TIME
 Continuous Improvement
is not always continuous!

Reality = “regress
Plan to “stablize” to old habits or
behaviors”

Revised slope
 Are your gains being sustained?

• Operating from crisis to crisis?

• Resistance to change?
• Abandoned Improvement efforts?
• “Meet the Numbers” No time to
Improve?
• Team based Culture?
• Silo Mentality?
• Processes Stable/Standardized?
• Costs under Control?
• Predictable Quality?
• Morale?
 “Sustain the Gains”
JI/JR

JM
Continuous
Improvement
JI/JR KAIZEN tools, focus
on process
$ development

JM TWI focuses
Complimentary
Lean Strategies on people
development
Project

TIME
 Lets take a look . . .

• JOB RELATION (JR) The TWI approach focus:

“Current Problems”
• JOB INSTRUCTION (JI) • Output
• JOB METHODS (JM) • Quality
• Scrap
• JOB SAFETY (JS) • Rework
• Cycle Time
• Relationships
• Standards
• Safety
 Job Relations (JR)

Helps supervisors /team leaders/others:

1. Maintain positive employee relations by evaluating
and taking proper actions
2. Solve and prevent problems, then resolve conflicts
when they arise.
Results:
• Improved employee relations and morale
• Fewer grievances
• Improved attendance
• Less equipment damage
• Improved productivity, quality, and profits
 How to Prevent Problems

• Let each worker know how he/she is doing

• Give credit when credit is due
• Tell people in advance about changes that will
affect them
• Make the best use of each person’s ability
 How to Handle a Problem

DEFINE YOUR OBJECTIVE

Step 1: Get The Facts Get the whole story

Step 2: Weigh And Decide Don’t jump to conclusions
Step 3: Take Action Don’t pass the buck
Step 4: Check Result Did your action help
production?

DID YOU ACCOMPLISH YOUR OBJECTIVE?

 Job Instruction (JI)

How to teach people to quickly learn to do a job

correctly, safely and conscientiously.

Results:
• Reduced training time • Less scrap and rework
• Increased production • Increased profits
• Fewer accidents • Less equipment and tool damage
• Increased job satisfaction/ • Standardized work
morale
• Quality consistency
• Improved quality
 How do we train our people?

• Shadow more experienced

worker? What does your
• Let HR do it? orientation
• Read the manual? program look like?
• Buddy system?
• Classroom instruction?
• Throw them over the wall? How is it working?
How we Instruct

TELLING
 Telling may not work by itself. . .

We also instruct by…

“SHOWING”
 How to Get Ready to Instruct

1. Make a Timetable for Training

2. Break down the Job
3. Get Everything Ready
4. Arrange the Worksite
 Break Down the Job

No. __________
JOB INSTRUCTION BREAKDOWN SHEET

Operation: _____________________________________ ___________

Parts: ____________________________________________________________

Tools & Materials: ______________________________________________

IMPORTANT STEPS KEY POINTS REASONS

Anything in a step that
might—
A logical segment of the
1.Make or break the job
operation when
2.Injure the worker Reasons for each key
something happens to
3.Make the work easier to point
advance the work.
do, i.e. “knack”, “trick”,
special timing, bit of
special information
HOW YOU DO IT
WHAT YOU DO And Why we do it that WHY YOU DO IT
way!
Training Timetable
 Job Methods (JM)

Trains supervisors/leaders how to analyze jobs to make

the best use of people, machines and material now
available.
Results:
• Reduced cost
• Reduced WIP
• Reduced inventory
• Increased throughput
• Increased profits
• Continuous improvement
 4 Step Method

1. Breakdown the Job

2. Question Every Detail
3. Develop the New Method
4. Apply the New Method
 STEP 1: Break Down the Job

Job Breakdown Sheet

PRODUCT: MADE BY: DATE:

OPERATIONS: DEPARTMENT:
REMARKS IDEAS

Rearrange
PRESENT/PROPOSED

WHERE

Eliminate

Combine

Simplify
WHEN
TIME/TOLERANCE/

tance

HOW
WHO
METHOD DETAILS

WHY
Write them down, don’t try to remember.

Dis-
REJECTS/SAFETY
 Step 2: Question Every Detail

Why is it necessary?
What is its purpose?

Where should it be done?

When should it be done?
Who is best qualified to do it?

How is “the best way” to do it?

 Step 3: Develop the New Method

Why?
Eliminate
What?

Where?
Combine
When? Rearrange
Who?

How? Simplify
 JM Improvement Proposal

Improvement Proposal Sheet

Submitted to:
Made by: Department:
Product/Part: Date:
Operations:

The following are proposed improvements on the above operations.

1. Summary

2. Results
Before Improvement After Improvement
Production (one worker per day)
Machine Use (one machine per day)
Reject Rate
Number of Operators
Other

3. Content
 Step 4: Apply the New Method

1. Sell the change to others

2. Obtain necessary approvals
3. Put the new method to use right away
4. Credit those involved
(Document the new standard,
then continue to improve the new method)
 The Three Original TWI Programs . . .

work together like a three-legged stool —

take one leg away and the stool falls down.
JS acts as the seat to hold it all together

JR – Positive Environment
JI – Stabilized Processes
JM – Continuously Improve
JS – Work Environment

(Developed by Toyota in the 1950’s)

 Job Safety (JS)

• Engaging employee’s in identifying potential safety

hazards and eliminating them.
• Breaking the chain of events that lead to incidents and
injuries.
• Builds improved work environments and staff confidence.
• Compliments current OSHA and EPA training and
regulations. TWI JS incorporates a methodology to
implement OSHA and EPA regulatory intentions.
• Increases safety awareness.
 Job Safety (JS)

“BREAK THE CHAIN”

Indirect Direct (Causes)

Items Causes Acts & Incidents Injuries
Conditions
 4 Step Method

STEP 1 SPOT THE CAUSES OF DANGER

STEP 2 DECIDE ON THE COUNTERMEASURES

STEP 3 ENFORCE COUNTERMEASURES

STEP 4 CHECK RESULTS

 JS is not OSHA Training

OSHA Training: 10 hour or 30 hour classes covering

……..Knowledge

Slips/Trips; Injuries: Electrical Hazards; Machine

Guarding; Haz Com; Backs/Ergonomics; Fire Danger;
Evacuations; PPE; General Duty Dangers; Access; etc.

JS covers skills to see the danger before it happens.

 Safety Analysis Table
ITEM INDIRECT DIRECT INCIDENT INJURY
CAUSES CAUSES

PEOPLE

THINGS

ESTIMATED
COUNTERMEASURES

COST

MONEY

TIME

THINGS

OTHER
 Sustain the Gains

• Enlist an internal Champion

• Set up a Steering Committee
• Pilot the efforts (Concentrated Focus)
• Roll out slowly (Minimize/control variation)
• Enlist accountabilities (Rules/policy)
• Audit the Process
 TWI - the Missing Link to Lean

Strategies don’t
(TWI Culture)
produce: People Do!

(Mortar)
Continuous Improvement
Continuous Improvement

Pull/Kanban Cellular/Flow TPM

POUS Quality at Source Quick Changeover

Standardized Work Batch Reduction Teams

Value
Stream
Visual 5S System Plant Layout Mapping
(Tools)
 How TWI Supports “Everyday Engagement

Gallup’s Employee Engagement Survey

1. I know what is expected of me at work. JI JR

2. I have the materials and equipment I need JI JM
to do my work right.
3. At work, I have the opportunity to do what I JI JR JM
do best every day.
4. In the last seven days, I have received JR
recognition or praise for doing good work.
5. My supervisor, or someone at work, seems JR
to care about me as a person.
6. There is someone at work who encourages JI JR JM
my development.
 How TWI Supports “Everyday Engagement

Gallup’s Employee Engagement Survey

7. At work, my opinions seem to count. JR JM

8. The mission or purpose of my company JI JR JM
makes me feel my job is important.
9. My associates or fellow employees are JI JM
committed to doing quality work.
10. I have a best friend at work. JR
11. In the last six months, someone at work JI JR
has talked to me about my progress.
12. This last year, I have had opportunities at JI JR JM
work to learn and grow.
TWI = Investment in Your People

• Indoctrinates people into an

“improvement” frame of mind.
• Teaches people how to identify
opportunities for improving their jobs.
• Trains people how to generate ideas
to take advantage of these
opportunities.
• Shows people how to get these ideas
into practice right away.
• Creates ownership for people to
maintain standard work.