webinar february 25, 2010 presenters: steve grossman and sam wagner

The Critical Role of the TWI Champions in a Successful

TWI Implementation

WebinarFebruary 25, 2010

Presenters: Steve Grossman and Sam Wagner

www.TWI-Institute.org

Outline for today 1. Introductions2. Training Within Industry

3. How does TWI Support Lean?4. What is a TWI Champion ? 5. Why is the TWI Champions Critical to Success?

The Critical Role of the TWI Champions


Outline for today 6. How are TWI Champions

Created? 7. What are the Key Tasks of

the TWI Champions?8. Donnelly Manufacturing9. Measuring Results 10. Q & A



1. IntroductionsSteve Grossman

Director of the TWI Institute

Sam Wagner Director of Advanced Manufacturing

Donnelly Custom Manufacturing



2. What is Training Within Industry (TWI)?

Standardized programs addressing the essential skills

needed by supervisors, team leaders, and anyone leading others.

The program is composed of four skill-based modules:

Job Relations (JR) Job Instruction (JI)

Job Methods (JM) Job Safety (JS)



3. How does TWI Support Lean?

TWI is more than the link that unites lean practice with the

training to sustain it. Actually, it is more like a

series of links that both hold the effort together and communicate the key

messages. It is the DNA of Lean





Quick Changeover

Standardized Work

Batch Reduction

Teams

Quality at SourceVisual Controls

Plant LayoutKaizen Event

POUS

Cellular/FlowPull / KanbanTPM

The Lean House of “Tools”

5S

PM

JIT

ValueStreamMapping

DTWI TWI TWI TWI TWI TWI TWI TWI TWI TWI TWI TWI TWI TWI TWI



TWI Is the Mortar the Holds the House of Lean Together

4. Who are the TWI Champions?

Corporate Site Manager

Gemba



TWI Champion at the Gemba

TWI Champion Site Manager

TWI Corporate Champion

Who are the Management TWI Champions?

The CEOs and managers who effectively communicate the importance of TWI and

dedicate the critical resources.






Who are the TWI Champions at the Gemba?

The Leaders and Supervisors who direct the work of others in the workplace and who are provided with the training and

time to implement TWI.






5. Why is the TWI Champion Critical to Success ?

No Champion =

No formal structure

No fully committed resources

No clear direction

No Certified J trainers



6. TWI Champions: How are they Created?

Initial TWI ten hour training New classification

Job Posting Screening for skills and abilities

Commitment by management to dedicate resources (time and training)

Champions may become certified in selected TWI programs



7. What are the Key Tasks of the TWI Champion?

Identification of priorities with Management

Creating JIBS (JI)

Focus efforts

Establish Training Schedules

Audit results



Provide Coaching Run the Steering Committee

Follow-up on training (both 10-hour classes and actual instruction of jobs)

Audit operator instruction and skill

…………………………………..

…………………………………..





8. Donnelly Manufacturing


Enjoy the Show!!!

Load ‘em up (the shells)Light ‘em up (the fuses)Get Out of the WayOooh and Ahhh!!




Load ‘em up!1. Define your objectives and link to your key business needs / critical success factors

• JR: leadership training for shop floor associates; address “fairness” and turnover

• JI: train better and faster for new associates and setups; improve quality

• JM: engage associates; improve value-add per employee, safety, quality

2. Involve Managers• Observe training• Develop training plan

3. Develop measurements4. Build into performance appraisals



Light the Fuses

1. Start the training• Go for density

2. Coach Managers / Supervisors how to encourage (and not discourage)

• Carry and refer to the card• Look for ways to use it• Don’t accept when it should be

used and isn’t• If too late, describe how it could

have helped3. Post visual measures4. Broadcast early successes



Get Out of the Way

1. Let your Supervisors own it, but strongly support:

• Training plan• Visuals• Core concepts

2. Let TWI adapt to your environment• Supervisory training• JI breakdowns as a training tool• JI training delivery versus

breakdown development• JM breakdowns

3. Track who is using it – and who’s not



Oooh and Ahhhh!1. Encourage ongoing Training and learning• Read books & articles• Blogs, webcasts• Peer councils• Seminars and conferences• TWI Summit3. Celebrate4. Brag about your team!!!



Enjoy the

Show!!!

Oooh and Ahhh

Get out of the way

Light ‘em up

Load ‘em up

9. Measuring Results

Exemplary TWI Companies Have Documented Improved Profits Through:

Customer Quality PPM Improvements Training Time Reductions

Rework ReductionsDefect Reductions

Setup Time ReductionsReduced Employee Turnover

Reduced AbsenteeismTakt Time Reduction

Lead Time ReductionsIncident and Accident Reductions



10. Questions ?



Thank You!

The TWI Institute in Partnership with



webinar february 25, 2010 presenters: steve grossman and sam wagner

Documents

twi champion critical

twi champions critical

initial twi

industry twi

importance of twi

management twi champions

twi support lean

selected twi programs