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The tool that helped us end world war II can help you become more productive and profitable
" You will not become Lean by doing TWI, but you will not become Lean without doing TWI. "
Jim Huntzinger
Productivity Author
In the early 1940’s, we suddenly needed to train thousands of unskilled workers to build the planes, ships, and materials needed to both support the war effort and keep America running.
US Industry quickly came together, stepped up, and developed TWI to meet the challenge.
At the battle of Midway, the US and Japan each lost all but 2 aircraft carriers. In the next two years:
Japan launched 6 new carriers
The US built:
The difference? TWI
In the 1950s, TWI was adopted by Japan to rebuild their industry. Since then, it has become a foundation element of Lean Manufacturing.
Unfortunately, American industry put TWI on the shelf after the war. Until now.
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Training Within Industry - TWI
TWI is a proven problem-solving tool which utilizes focused training methods to help employees better understand and complete their daily work processes.
It consists of four complimentary, skill-based standardized programs addressing the essential skills needed by supervisors, team leaders, and anyone indirectly leading others.
Each of the programs:
- is taught in five, 2-hour sessions
- uses a hands-on “learn by doing” format
- uses real life, company-specific examples
- provides learning reinforcement through repetitive practice in the workplace
- promotes team work and cross-training
TWI complements Lean by providing frontline personnel with the skill set to establish a culture for change, improve methods, and facilitate standard work. It also provides the framework for employees to integrate Lean Principles into their daily work activities.
The Benefits
Businesses invest in training to improve quality, delivery, cost, morale, and safety. Typically the return on investment of training initiatives is hard to measure and occurs long after completion. Not so with TWI.
Companies adopting the three primary modules of TWI have had unprecedented success including cost savings, productivity improvements, scrap and waste reduction, energy reduction, employee retention, and cost avoidance.
Of 600 companies implementing TWI over a 4 year period:
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86% increased production by at least 25%
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100% reduced training time by 25% or more
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88% reduced labor-hours by over 25%
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55% reduced scrap by at least 25%
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100% reduced grievances by more than 25%
The bottom Line? TWI will provide you with immediate savings in cost and time which will translate directly into improved productivity and profitability.
The Programs
The TWI programs provide a comprehensive solution to meeting the needs of supervisors, team leaders, and other indirect leaders. Our TWI Institute-Certified Trainers assure that the training is delivered to high quality standards and that the proven TWI methodology is followed.
Each program is taught in five 2-hour sessions over the course of a 5-day week. After each daily session, trainees return to the workplace to use the techniques learned and choose real life examples to discuss and practice together in class. This proven format significantly enhances both knowledge retention and the effectiveness of the training.
The primary training modules include:
Job Instruction (JI): teaches supervisors how to quickly train employees to do a job correctly, safely, and conscientiously
Job Methods (JM): teaches supervisors how to produce a higher quality of products in less time by making the best use of available people, machines, and materials
Job Relations (JR): teaches supervisors how to build positive employee relations, increase cooperation and motivation, and quickly resolve conflicts.
Job Safety (JS): teaches supervisors how to instruct preventative measures that can help reduce safety incidents and improve overall work quality.
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TWI = Competitive Edge
Simply put, a Training Within Industry (TWI) initiative is one of the fastest, most effective means of improving productivity, quality, and profitability that you can implement.
In a manufacturing environment, TWI results in less scrap, fewer accidents, less tool and equipment damage, and improved productivity.
In an office environment, TWI results in fewer errors made, task completed in a more consistant, timely manner, and cross-training is standardized.
By implementing a focused training strategy, you can ensure that your employees have the necessary information, knowledge, and skill sets to meet the competitive challenges of today's business world.
What will it cost?
While every engagement is different, we know how to best tailor solutions to meet your needs and minimize costs. We also apply our ability to obtain incentives, tax credits, grants, and other funding from various local, state, and federal programs to help clients offset engagement costs and accelerate pay back.
Instead of cost, we should really talk about your return on investment and how to achieve it. That is the only way you can make an informed decision on whether TWI is right for you.
Contact us today to learn how a TWI initiative can improve your competitivness and profitability.
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