Launching a TWI Job Instruction Program at Hallmark Cards

TWI SUMMIT

LAUNCHING TWI JOB INSTRUCTION AT HALLMARK CARDSPaul Riley

HALLMARK CARDS, INC.

WHY TRAINING?

• Improved proficiency – production – quality – cost – safety • Standard work - stabilized performance – consistency –

continuous improvement• Employee engagement – morale – retention – investment

in people

5

A production Center

training and development

program based on

clearly defined

standard work and TWI

Job Instruction

method that enables

Hallmarkers to increase productivity

by 25% through

continuous improvement.

Future State

Conditions/ Major

Objectives

Lines of Effort and Intermediate Objectives

Current State

Clearly Developed STW and

JIBs

Trained/ Certified Trainers

Established Process and Organization

Initial and Cyclical

Certification

Continuous Improvement and Retraining

Create/Update STW

Classify/Analyze Job

In most cases, a practice of on the job

training based on individual know-how of

assigned operators with

little formal verification of learning and resulting in

variable performance and limited opportunity

for continuous improvement.

Develop JIBs

Validate JIBs

Auditing

ID/SelectJI Trainers

Certify MTs(40 hrs)

Coach/MentorJI Trainers

Prepare the Organization

Develop Training Plan

Apply/Execute in Work Area

Verify Learning and Success

Establish Audit Plan

Develop Training Program Audit

Track and Repeat

Assess and Certify

Prepare Assessment

Tool

ID Certification Points

Detect Opportunity to Improve

Reflect/ActConduct Audits

Update STWEvaluate Results

Test New STW

Retrain/ Recertify

1.1

4.34.24.1

3.43.33.23.1

2.42.32.1

1.41.31.2

6.26.1

5.45.35.25.1

4.4

6.56.46.3

2.2

Train Trainers and Leaders (10 hrs)

6

Launch of TWI JI in Counter Packaging

OCTOBER

2019

40-Hour Train-the Trainer Course

DECEMBER

2019

Additional trainers developed

JANUARY

2020

Launch of TWI JI in Virko 1-Up

FEBRUARY

2020

Additional trainers developed

JUNE

2020

Launch of TWI JI in Lithography

JUNE

2020

Additional trainers developed

SEPTEMBER

2020

Launch of Packer training in Packaging

NOVEMBER

2020

100th Hallmarker trained!

DECEMBER

2020

Launch of TWI JI at Kansas City in

Engineering

JANUARY

2021

Launch of TWI JI in Resealable

FEBRUARY

2021

Launch of TWI JI at Leavenworth in Tissue

FEBRUARY

2021

OUR PROCESS

• Resourcing and Commitment

• Analysis and Selection of Areas

OUR PROCESS

• Communication• Training to Standardize• Selection and Recruitment

OUR PROCESS

• Communication• Training to Standardize• Selection and Recruitment

NATURAL TALENTS LEARNABLE SKILLS AND ABILITIES

SELECTING TRAINERS

• Willing and Able to Learn• Adaptable and Flexible• Genuine Caring and Concern

for Others• Patience• Persistence• Taking Responsibility• Confidence and Leadership• Questioning Nature

• Observation and Job Analysis Ability

• Effective Communication Skills• Attention to Detail• Knowledge of the Job• Respect of Fellow Employees

As published in the book, “Toyota Talent”

OUR PROCESS

• JITC and Launching• JIB Development and

Trainer Certification• Pre-Training Meetings

OUR PROCESS

• Job Instruction and Certification

• Record Keeping

RECORD KEEPING

OUR PROCESS

• Data Collection and Analysis

• Continuous Improvement

MEASURING PROGRESS

MEASURING PROGRESS

20

THE SEEDS OF TRAINING ARE BITTER, BUT THE FRUIT IS SWEET

21

June spike due to change in work mix.

THE SEEDS OF TRAINING ARE BITTER, BUT THE FRUIT IS SWEET

THE SEEDS OF TRAINING ARE BITTER, BUT THE FRUIT IS SWEET

23

LESSONS LEARNED• Alignment with

Production• Time to apply and run

after training• Manufacturer (OEM)

training• Training on new

equipment

LESSONS LEARNED• Training on familiar

equipment• Doing JI on three

shifts• Facilitating

collaboration between JI trainers

LESSONS LEARNED• Engagement and

Inclusion• Coaching and follow up• Capacity to develop

trainers• Troubleshooting JIBs• Dry Erase Boards• 10-hour course

dynamics