LEAN AND TWI
Before going too far down the road with Lean a company should ask:
1. Do we have trained employees available to handle the current processes?
2. Do we have work methods such as basic work instructions and standards in place?
If the answer to these questions is no, you do not have a consistent and predictable process and therefore need to link your Lean Initiative with TWI JI.
WHAT IS TRAINING WITHIN INDUSTRY (TWI)?
TWI is a standardised program initiated in the 1940s in the USA in response to the demand for a replacement skilled workforce to meet the requirements of the forces during WW2. The program focuses on 3 essential skills:
1. Skill in leading – Job Relations (JR)
2. Skill in instructing-Job Instruction (JI)
3. Skill in improving methods (JM)
Job Relations (JR)
Create a positive work environment receptive to change. Learn the skill of building and maintaining positive employee relations by directly tackling real issues. Use JR can increase output, improve attendance figures, achieve better workplace morale with higher employee retention rates.
Job Instruction (JI)
Stabilise and standardise work methods by training workers how to quickly remember how to perform tasks correctly, safely and conscientiously. Rather than push information onto employees it is more important that they “learn how to learn”. Using JI can reduce training time, reduces waste, reduces rework, results in fewer workplace accidents and increases job satisfaction.
Job Methods (JM)
Sustain the standardisation and improve work methods by improving the way tasks are done. Break down jobs to determine tasks that can be eliminated, combined, rearranged or simplified resulting in an optimum method-based on what we know today. Using JM can reduce cost, increase productivity, reduce time taken to complete a task and supports workplace continuous improvement.
WHY USE TWI?
Focuses people into an “improvement” frame of mind.
Teaches people how to identify opportunities for improving their jobs.
Trains people how to generate ideas to take advantage of these opportunities.
Shows people how to get these ideas into practice right away.
Creates ownership for people to maintain standard work.
The TWI approach is not a matter of schools, classes or lessons –
TWI is about individual and/or group work on current day problems of output, quality, lost-time, scrap, re-work, maintenance, and working relations.
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