This intensive course for managers and directors will help them improve shop floor management. Training Within Industry (TWI), has been a significant part of the culture at Toyota and other world class companies for developing the capabilities of managers and leaders. TWI provides the essential skills in instruction, methods improvement and leadership needed by all supervisors, first level managers, foremen or team leaders, regardless of industry, and consists of the three following programs:
The Job Instruction (JI) program teaches supervisors proper workforce training techniques. The objective is to help them develop a well-trained workforce, producing less scrap, rework, and rejects while having fewer accidents and less tool and equipment damage. The method emphasizes preparing the operator to learn, giving a proper demonstration while identifying the Important Steps and the Key Points of the job, having the operator perform a trial run, and tapering off coaching while continuing to follow up.
The Job Relations (JR) program teaches supervisors a path of leadership that results in improved worker motivation and involvement in problem solving. Recognizing that supervisors get results through people, the program emphasizes that people must be treated as individuals and teaches supervisors how to build a foundation for developing and maintaining good job relations. When used every day, these foundations prevent many problems from arising. However, when problems do arise, supervisors are taught to get the facts, then weigh and decide, take action, and check results with the key issue being whether the action taken helped production.
The Job Methods (JM) program teaches supervisors how to improve the way jobs are done. The aim is to produce greater quantities of quality products in less time by making the best use of the labor, machines, and materials now available. Supervisors are taught how to break down jobs listing every detail, to question each of these details using 5W1H (why? what? where? when? who? how?), to then develop a new method by eliminating, combining, rearranging and simplifying these details, and to apply the new method selling it to everyone involved.
The three TWI programs are structured in the same way following a proven “learn by doing” approach. In this course, the participants experience the first session of each program. The instructor presents a real-world problem that everyone can easily relate to and shows the poor ways in which these problems are usually handled. Then, the proven TWI “4-Step Method,” one for each of the three programs, is given to show how supervisors can handle such problems more effectively and gain better results. Making TWI part of your management system will enhance your competitiveness through the following benefits:
Less time to train people to production level with fewer mistakes
On-the-job training performed to a standard
Lean Manufacturing Standard Work that is sustained
Better use of resources without spending money
Managers and Workers who are more effective
Improved management of daily work routine
An engaged workforce and better morale
More effective Managers & Workers
Job training standardized
Human Resources Managers
Manufacturing team leaders
How to get the most from this course
Participate in at least one improvement activity.
Conduct or participate in at least one on-the-job training session with a line employee.
Review your company's challenges in hiring, training and retaining the shop floor workforce
Read an introduction to lean manufacturing
Bring an open mind.
Course outline (click on blue bullets for details)