webinar february 25, 2010 presenters: steve grossman and sam wagner
TRANSCRIPT
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
www.TWI-Institute.org
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
The Critical Role of the TWI Champions
www.TWI-Institute.org
1. IntroductionsSteve Grossman
Director of the TWI Institute
Sam Wagner Director of Advanced Manufacturing
Donnelly Custom Manufacturing
The Critical Role of the TWI Champions
www.TWI-Institute.org
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)
The Critical Role of the TWI Champions
www.TWI-Institute.org
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
The Critical Role of the TWI Champions
www.TWI-Institute.org
The Critical Role of the TWI Champions
www.TWI-Institute.org
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
DTWI TWI TWI TWI TWI TWI TWI TWI TWI TWI TWI TWI TWI TWI TWI
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
The Critical Role of the TWI Champions
www.TWI-Institute.org
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.
The Critical Role of the TWI Champions
www.TWI-Institute.org
TWI Corporate Champion
TWI Champion Site Manager
TWI Champion at the Gemba
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.
The Critical Role of the TWI Champions
www.TWI-Institute.org
TWI Corporate Champion
TWI Champion Site Manager
TWI Champion at the Gemba
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
The Critical Role of the TWI Champions
www.TWI-Institute.org
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
The Critical Role of the TWI Champions
www.TWI-Institute.org
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
The Critical Role of the TWI Champions
www.TWI-Institute.org
Provide Coaching Run the Steering Committee
Follow-up on training (both 10-hour classes and actual instruction of jobs)
Audit operator instruction and skill
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The Critical Role of the TWI Champions
www.TWI-Institute.org
www.TWI-Institute.org
Enjoy the Show!!!
Load ‘em up (the shells)Light ‘em up (the fuses)Get Out of the WayOooh and Ahhh!!
The Critical Role of the TWI Champions
www.TWI-Institute.org
The Critical Role of the TWI Champions
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
www.TWI-Institute.org
The Critical Role of the TWI Champions
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
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The Critical Role of the TWI Champions
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
www.TWI-Institute.org
The Critical Role of the TWI Champions
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!!!
www.TWI-Institute.org
The Critical Role of the TWI Champions
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
The Critical Role of the TWI Champions
www.TWI-Institute.org