Title: TWI Job Instruction (JI) Training
Description: This four-day (1/2 days) hands-on class teaches the process for creating effective Job Instructions. Participants will learn this four-step method using a part or process they bring to the class. They will walk away with a complete Job Instruction breakdown sheet for the part/process of their choice.
Date: July 9 – 12th
Time: 8am – 11:30am
Location: Portland Bottling Company: 1321 NE Couch St, Portland Oregon
Cost: $450 per person*
Overview: The Training Within Industry (TWI) programs were developed in the United States sixty years ago and played a major role in boosting industrial production to the levels required to win the Second World War. After the war, they were introduced around the world and, most notably, are still in wide use in Japan today. The Toyota Production System approach of going to the source, observing in detail, and learning by doing was very much influenced by TWI and became the backbone of Toyota’s standardization philosophy. As such, TWI has a new role for US companies looking to implement Lean Manufacturing.
TWI has been called the Cornerstone of Lean Culture. TWI recognizes that supervisors and team leaders have five basic needs to be effective. Two of these needs are Knowledge of the Work and Knowledge of Responsibilities. These are unique to each company and/or industry and are therefore provided locally. Supervisors also need Skills in order to perform within their role, regardless of their industry. These skills are taught by TWI.
Key Concepts for Job Instruction (JI)
- Quickly training employees to do a job correctly, safely, and conscientiously
- Demands of developing a flexible workforce and training employees require standard work. Program attendees are taught how to effectively breakdown a job and deliver instruction for individual tasks. Developing and delivering training in this structured fashion fosters the conditions for process stability.
- The objective of the course is to help companies develop a well-trained workforce: have less scrap, rework, and rejects; have fewer accidents; have 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.
- Training Time, Rework, Operator Error (PPM):
- Job Instruction has a high impact on standard work and training time. Implementation of this program will drive several metrics including time to proficiency, and increased quality. The additional benefit of minimizing rework is accomplished by having the currently best known process utilized by all operators. Commonly, the root causes for many quality issues are defined as operator errors. Training to standard work will allow the company to drill beyond the typical problem and address process short comings to further reduce ppm defects and simultaneously reduce rework. Sustainability is the result of making the best currently known method the standard and training all operators in the same way.
Benefits experienced when practicing Job Instruction are reduced training time, less scrap and rework, fewer accidents, increased job satisfaction, and can be seen indirectly on the productivity and capacity metrics.