Posted by William Mullane | June 26, 2014
Training Within Industry (TWI) can be the missing link of Lean that produces a sustainable improvement over time.
Workplace Symptoms That Show a Need for TWI:
- Inconsistent production results
- Excessive rework
- High employee turnover
- Low employee moral
- What is TWI? – Excellent Overview Here
Hire, Train & Retain Great Employees
To be competitive in today’s global market, it is more important than ever to hire, train and retain great employees. TechHelp has helped hundreds of Idaho companies train frontline workers in the disciplines of advanced manufacturing. Businesses adopting TWI have consistently increased productivity, reduced training times and improved morale.
TWI is a dynamic program that uses a learn-by-doing approach to teach essential skills for supervisors and team leaders from all industries.
TWI is composed of three programs:
These programs work together to help supervisors build and maintain positive employee relations, train workers to quickly remember how to perform jobs correctly and safely & conscientiously improve the ways in which jobs are done.
- TechHelp offers “one-stop shopping” that delivers TWI as part of a Lean or Lean Six Sigma Transformation.
- With its experienced specialists, University partnerships and affiliation with the national Manufacturing Extension Partnership – TechHelp can bring world class expertise to all corners of Idaho.
- TechHelp specialists can be an “extension” of your staff; available where you need them and when you need them at an affordable price.
David O’Connell, above, of TechHelp and Idaho State University, has taken a particular interest in TWI and made it one of his primary areas of practice. As an accomplished Lean Practitioner, David has seen the unique role TWI can play in creating a workforce that is well trained, cross-trained, highly motivated and productive.
If you are interested in learning more about how TWI can help you train and retain great employees, contact David today at 208-589-5567 or firstname.lastname@example.org
What Does it Do?
Training Within Industry quickly and effectively trains supervisors in:
- Skills in Improving Methods – Job Methods (JM) teaches the skills needed to analyze jobs to make the best use of resources.
- Skills in Leading – Job Relations (JR) teaches the skills required to evaluate and take action to handle and prevent people problems.
- Skills in Instructing – Job Instruction (JI) teaches the skills needed to develop a well-trained workforce quickly.
- Reduces training time.
- Standardizes training.
- Increases productivity.
- Improves morale.
What Does it Solve?
- Effects of poor training – mistakes, poor quality, rework, scrap…
- Inconsistent handling of employee issues – uses 4 step JAR method to ensure all issues are handled in a common way
- Long learning curve for new supervisors – Gets supervisors up to speed fast
TWI was developed in the U.S. during WWII to train replacements of an industrial workforce off fighting a war. It provided rapid and consistent training and is recognized as part of what helped the Allied forces secure victory as they boosted industrial production and out-produced the enemy. TWI was an unqualified success.
Expansion in Japan
TWI was introduced in Japan during post-war rebuilding. It is still in widespread use in Japan; most notably at Toyota as part of the Toyota Production System (TPS). It is a foundation to Toyota’s success in continuous improvement, and more importantly, in its ability to sustain those improvements.
A prosperous post-war America gradually lost interest in TWI. But today’s competitive global marketplace is forcing U.S. managers to adopt the best tools available to hire, train & retain great workers. In what has been described as a “movement,” Lean enterprises nationwide are increasingly turning to TWI as a means to emulate Toyota’s ability to sustain improvements and achieve standard work. Industries such as health care, construction, and manufacturing are reaping modern day benefits from this proven and recently revived program.
Who Will it help?
- Anyone in a position where they direct and plan the work of others.
- Any company adding workers
Impact of TWI
1,750,650 people trained in 16,511 plants and unions
Of 600 companies monitored:
- 86% increased production by at least 25%
- 100% reduced training time by 25% or more
- 88% reduced labor hours by at least 25%
- 55% reduced scrap by at least 25%
- 100% reduced grievances by more than 25%