About the Course

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You have invested in Lean training for your employees. You have undertaken serious efforts to implement continuous improvement within your organization. Training Within Industry (TWI) is the next link in creating and sustaining a Lean Enterprise. This three-component program is the ideal process for training people within your industry who are responsible for training others in job skills, monitoring, and effectively managing continuous improvement initiatives, and doing so with consistent and proven results.

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• TWI has proven results in manufacturing, medical services, hotels and restaurants, and construction.

• Some benefits of TWI include:

  • 86% of companies increased production by at least 25%,

  • 100% reduced training time by more than 35%, 

  • 55% reduced scrap by at least 25%.

• TWI is recommended for anyone who is responsible for teaching another person a job or method, improving a job or method, and/or dealing with other employees.

 

TWI Modules

TWI includes four modules of training that teach basic skills to help supervisors and other employees make the transition from hierarchical "command & control" organizations to flatter, team-oriented organizations. These courses/modules are comprised of Job Instruction, Job Methods, Job Relations, and Job Safety.

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Overview

 

Job Instruction teaches supervisors how to quickly train employees to do the job correctly, safely, and conscientiously.

The objective of the course is to train employees how to teach someone a job or method. Knowing how to do something does not mean that we know how to teach someone else how to do it. The method emphasizes preparing the operator to learn, giving a proper demonstration while identifying the Important Steps and the Key Points of the job, having the operator perform a trial run, and tapering off coaching while continuing to follow up. Well-trained employees have less scrap, rework, rejects and equipment damage and fewer accidents.

 

Agenda

The Job Instruction course is broken into five two-hour sessions.

 

First Session

• Explain the five needs of good supervisors

1. Knowledge of the Work

2. Knowledge of Responsibilities

3. Skill in Leading People

4. Skill in Improving Methods

5. Skill in Instructing

• Importance of JI training to production and safety

• The ability to train others is a personal asset

• Demonstration of faulty instruction

• Demonstration of correct instruction

• Introduce the Four-Step Method for Correct Instruction: 

1. Prepare the Worker 

2. Present the Operation 

3. Try-out Performance

4. Follow up

 

Second Session

• Two participant-instruction demonstrations from their workplace

• Class review of how they applied the four-step method to reinforce class learning

• Class practice on how to make Job Breakdowns for training purposes

• The four things a trainer must do to “get ready” to train others: 

1. Make a Timetable

2. Break down the Job

3. Get everything ready

4. Arrange the worksite

 

Third Session

• Teach class how to construct and use a Training Timetable

• Three participant-instruction demonstrations from their workplace

• Class review of how they applied the four-step method to reinforce class learning

 

Fourth Session

• Four participant-instruction demonstrations from their workplace

• Class review of how they applied the four-step method to reinforce class learning

 

Fifth Session

• Remaining participant workplace instruction demonstrations facilitated to be correct

• Importance of starting to use good Job Instruction “right away” for production and safety

• Create conviction for using the Job Instruction Plan on a continuing basis

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