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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
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