The TWI Workbook

Synopsis

<p>Since the publication of its Shingo Prize-winning predecessor, TWI programs have seen steady growth in usage. As a true understanding of Standard Work has developed, the need for the TWI skills as fundamental tools to achieve Lean objectives has been solidified.<br><br><strong>The TWI Workbook: Essential Skills for Supervisors, Second Edition</strong> has been completely updated to the latest terminology and practice. This edition includes revised forms and tools, as well as new examples that illustrate current day TWI practice. Emphasizing the importance of accident and injury prevention, this edition includes an entirely new section on Job Safety, a fourth TWI module that was developed in Japan using the identical TWI methodology of the original three programs introduced in the original work. This updated edition includes new chapters on:</p><ul> <li>Four Steps of Job Safety: Preventing Accidents before They Happen</li> <li>Two Key Aspects to Safety: Things and People</li> <li>Practicing the JS Method</li> <li>TWI’s Problem Solving Training</li> </ul><p>In addition to a new chapter on the TWI problem-solving methodology, this edition contains a new introduction with a more complete description of how TWI was reintroduced into American industry, including detailed information on the contribution TWI made at Toyota that was not available when the original book was published.<br><br>Focusing on how the TWI skills create and support standardized work as the foundation for Lean and continuous improvement, the book includes detailed explanations on how to determine important steps and find key points that lead the way to standardized work. A new section on making a balanced breakdown has also been added, with new examples of Job Instruction breakdowns. The book also features a new conclusion that compares the historical role of TWI with what companies today are experiencing using the TWI methodology.</p>

Summary

Chapter 1: Introduction

This chapter introduces the TWI (Training Within Industry) program, its history, and its benefits. It explains that TWI is a structured training system designed to improve the effectiveness of supervisors and managers.

Example: A manufacturing company introduces TWI to train its supervisors on how to effectively manage their teams and improve production efficiency.

Chapter 2: Job Instruction

This chapter covers the 4-step process of job instruction (JI):
1. Prepare the learner to receive instruction.
2. Present the operation in a clear and logical manner.
3. Have the learner perform the operation while receiving feedback.
4. Get the learner to explain the operation back to the instructor.

Example: A maintenance technician teaches a new employee how to replace a faulty component on a machine. The technician follows the JI process, ensuring the employee understands each step and can perform the task independently.

Chapter 3: Job Methods

This chapter teaches the 5-step process for improving job methods:
1. Identify the problem or improvement area.
2. Analyze the problem in detail.
3. Develop a new or improved method.
4. Test the new method and make necessary adjustments.
5. Implement the new method and follow up on its effectiveness.

Example: A warehouse team notices frequent delays in loading trucks. They use the JM process to identify the bottleneck, develop a more efficient loading sequence, and reduce the loading time significantly.

Chapter 4: Job Relations

This chapter focuses on improving teamwork and resolving workplace conflicts. It provides a 4-step process for handling grievances:
1. Allow the employee to express their grievance fully.
2. Get all the facts from multiple perspectives.
3. Analyze the facts and identify the root cause of the grievance.
4. Make a fair and equitable decision and explain it to the employee.

Example: A supervisor mediates a conflict between two employees over work assignments. By following the JR process, they uncover the underlying issue, find a mutually acceptable solution, and restore harmony to the team.

Chapter 5: Leadership

This chapter discusses the role of effective leadership in organizations. It highlights the importance of setting clear goals, providing guidance, and inspiring and motivating employees.

Example: A team leader sets clear performance expectations, provides regular feedback to team members, and encourages collaboration. By establishing a positive and supportive work environment, the team leader fosters productivity and engagement.

Conclusion

The TWI Workbook concludes by emphasizing the transformative power of training and its impact on organizational success. It encourages organizations to adopt and implement the TWI principles to enhance the skills and effectiveness of their supervisors and managers.