Training Within Industry (TWI), a dynamic, "hands-on,  train-the-trainer" program, was developed in the United States in the early 1940’s to boost World War II industrial production. It was an unqualified success. After the war, the program was exported to Japan, where it was used extensively to rebuild that country’s industrial base. During the early 1950’s, TWI was used to train employees in the Toyota Production System.

Still in use in Japan, it is now being rediscovered by American manufacturing companies and used to leverage their Lean Enterprise Continuous Process Improvement programs.

To increase their competitive position in today’s global marketplace, companies in all industries are implementing the Lean and Six Sigma tools for continuous improvement. Some have difficulty getting started and others struggle to maintain the improvements that they make. Before the Lean and Six Sigma tools and techniques can be truly effective, an organization must have a stable, well trained workforce, including effective team leaders and supervisors.

The key is to improve the skills of the supervisor in order to improve the capabilities of the entire work team.The TWI programs provide the stability to get started and the standardization to sustain the improvements. 
 

TWI consists of three standardized programs (modules) that cover the essential skills needed by supervisors, team leaders and all who direct the work of others, regardless of their industries. These are skill in instruction; improving methods; and leading. Each module is delivered in a series of five 2-3 hour sessions presented on consecutive days.

To help supervisors and team leaders develop these skills, TWI incorporates a four-step process, preparation, presentation, application and testing in each of three modules.

Module One – Job Instruction (JI) Training teaches supervisors how to quickly train employees to do the job correctly, safely and consistently. Supervisors are taught how to effectively break down a job for instruction. The method emphasizes preparing the employee to learn, giving a proper demonstration, identifying the key points in the job, observing the employee in trial runs and gradual reductions in coaching while continuing to follow up.

Module Two – Job Method (JM) Training teaches supervisors how to improve the way jobs are done and help produce greater quantities in less time by the best use of people, materials and machines available. Supervisors are taught how to break down jobs into their constituent operations and to develop new methods by eliminating, combining and rearranging these operations.

Module Three – Job Relations (JR) Training teaches supervisors that people must be treated as individuals and how to build positive employee relationships, increase cooperation and motivation as well as effectively resolve conflicts. Supervisors are taught to give constructive feedback and credit, to tell people in advance about changes that will affect them and are shown ways to make the best use of each person’s abilities and to earn loyalty and cooperation.

In the manufacturing community, the success of the Toyota Production System is well known as is the role that TWI has and continues to play there. Less well known, but equally impressive, is the success of TWI during World War II in America. For instance:

• 86 percent of the companies using TWI increased production by at least 25 percent;
• 100 percent reduced training time by more than 25 percent;
• 55 percent reduced scrap by at least 25 percent; and
• 100 percent reduced grievances by more than 25 percent.

Companies that have rediscovered TWI and are using it today are realizing similar results in reducing absenteeism, employee turnover, training time, rework and operator error and improving productivity, cost and quality.

To begin your TWI experience, your Missouri Enterprise Area Business Manager and a certified TWI specialist will conduct an assessment of your company’s current status, strengths, resources, short and long term needs and will present a detailed project proposal and cost quotation.

And, since we are experienced “Lean Enterprise,” Six Sigma and Quality Management Systems professionals, we can help you integrate these tools into your overall TWI experience.