An Overview of Training Within Industry - LEAN Gov Center _Training (1).pdf · TWI An Overview of Training Within Industry Steven Grossman EdD Susan Janus August 12, 2011

TWI

An Overview of Training Within Industry

Steven Grossman EdD Susan Janus

August 12, 2011

www.TWI-Institute.org www.massmep.org2

Introductions TWI LEAN

Today’s Journey


Introductions

www.TWI-Institute.org www.massmep.org 4

TWIEst. 1940

Walter Dietz


The real job had to

be done by industry, within industry.


B-17



We Did lt !


Toyota Production

System

TWI found new life in Japan


Definition:“A supervisor is anyone who is in charge of, or directs the work of others”

TWI Original Focus:

“Five Basic Needs of Supervisors”


KNOWLEDGE SKILL

Work

Responsibilities

Instructing

ImprovingMethods

Leading

Safety

Five Basic Needs


How to teach

a person to do a job

correctly,

safely,

and conscientiously

Job Instruction Training (JI)


How to analyze jobs

to make the best use of the

people, machines, and

materials

currently available

Job Methods Training (JM)


How to build positive

employee relations, increase

cooperation and motivation,

and effectively resolve

and prevent people

problems

Job Relations Training (JR)


How to identify the

direct and indirect

causes of incidents and

injuries and

prevent them

from happening

Job Safety (JS)



A Closer Look at Job Instructions (JI)

Using 4-Step Method

JobBreakdowns

TrainingTimetable

How To Instruct

How To Prepare

“If the worker hasn’t learned, the instructor hasn’t taught”


How to Instruct

4-Step Method


No. __________

JOB INSTRUCTION BREAKDOWN SHEETOperation: _________________________________________________

Parts: _____________________________________________________________

Tools & Materials: ______________________________________________

What How WhyREASONSKEY POINTSIMPORTANT STEPS

Job Breakdown

= Script


TrainingTimetable


Attract / Trainable

Develop / Able

Engage / Improving

Enroll / Committed

Engagement of Employees


Standardized Work

TWI

STANDARDIZED WORK

CHART

PROCESS Cycle Time TAKT TimeSAFETY QUALITY IN PROCESS

Glost Kiln Operator Cycle 30-minutes 1-cycle / 90-

minutes

Element

Number

Description Work Time Walk

TimeWORK AREA LAYOUT

1 Walk to GK #3 Exit 1.0

2 Discharge Car from GK#3 5.0

3 Discharge Car from GK#4 5.0 1.2

4 Record GK#4 car numbers and

temps1.0 0.7

5 Charge GK#4 5.0 0.3

6 Charge GK#3 5.0 1.0

7 Record GK#3 car numbers and

temps1.0 0.6

8 Return to loading 0.6

Total (min): 22 5.4COMMENTS:

Safety: Use high temp gloves, pusher to move cars and be mindful for oily/slick surfaces

Quality: Inspect kiln cars and repair downed ware and refractory. Use care not to damage glaze of unfired ware

GK#4

GK#3

ENTRANCE

ENTRANCE

EXIT

EXIT

1, 8

2

3

4

5

6

7

Panel Board

Panel Board

Load Station

Load Station


Standardized Work –

What to Do


Job Instruction Training

Highly Skilled Associates

Best Method

Standardized Work

Analysis Tool

Baseline for

Continuous

Improvement

Job Redesign

Eliminate Waste

Focus: Daily Waste Elimination

Focus: Capability & Talent


Sustain TWI JI & JR

Potential of

Underutilized

People

Sustainment and Daily Improvement

Time

New Standard

What the Standard becomes

Gradually Improve of the Standard, TWI JM

Improvement Event

Perfo

rmance / O

utp

ut

Next Improvement Event



Results!TWI =


JI: Setup Operator Training at Albany International Monofilament Plant

0

5

10

15

20

25

Q4 '06 Q1 '07 Q2 '07 Q3 '07 Q4 '07 Q1 '08 Q2 '08 Q3 '08 Q4 '08

Human Error

JIMentoring

Begins

JIIntroduced

Results!


Results!


0

50

100

150

200

250

Jan-0

6

Mar-

06

May-0

6

Jul-06

Sep-0

6

Nov-0

6

Jan-0

7

Mar-

07

May-0

7

Jul-07

Sep-0

7

Nov-0

7

Jan-0

8

Mar-

08

May-0

8

Jul-08

Sep-0

8

Nov-0

8

Jan-0

9

Mar-

09

May-0

9

Jul-09

Sep-0

9

# o

f S

ub

mis

sio

ns

JM: Proposal Submissions

Results!


Falls and Falls w/Injury per 1000 Patient Days

Results!

0

0.5

1

1.5

2

2.5

3

3.5

4Ja

n 0

9

Feb 0

9

Mar

09

Apr

09

May 0

9

Jun 0

9

Jul 09

Aug 0

9

Sep 0

9

Oct

09

Nov 0

9

Overall Average Falls Per 1000

Overall Average Falls Per 1000 with Injury

TWI JIRounding Training


Results!

Reduced

Turnover


Results!

Reduced

Turnover

ReducedAccidents

ReducedComp


Results!Reduced

Turnover

ReducedAccidents

ReducedComp

ReducedRework

ReducedScrap


Results!

Reduced

Turnover

ReducedAccidents

ReducedComp

ReducedRework

ReducedScrap

ReducedSetup Time

ReducedTakt Time


Results!

Reduced

Turnover

ReducedAccidents

ReducedComp

ReducedRework

ReducedScrap

ReducedSetup Time

ReducedTakt Time

ImprovedMorale

Improved Profits


The TWI Workbook:

Essential Skills for

Supervisors

Shingo Research and

Professional

Publication Prize

2007

Implementing TWI:

Creating and

Managing a Skills

Based Culture

By Patrick Graupp

and Robert J. Wrona

QUESTIONS?

MassMEP: “Lean Management In the Fast Lane”

Pit Crew Challenge

An Overview of Training Within Industry - LEAN Gov Center _Training (1).pdf · TWI An Overview of Training Within Industry Steven Grossman EdD Susan Janus August 12, 2011

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