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DMC management consulting s.r.o., All rights reserved.
Implementing TWI (Training Within Industry) in the CEE Region - the basics of the methodology
Jitka Tejnorová
TWI Institute Czech Republic
2017
DMC management consulting s.r.o., All rights reserved.
Content
1General
2Job Instruction
3Job Relations
• DMC management consulting• Trainers• TWI Institute Central Europe• TWI philosophy
• Method description• Implementation• Follow-up activities• Results
• Method description• Implementation• Follow-up activities• Measurable indicators• Results
4Job Methods
• Method description• Implementation• Follow-up activities• Measurable indicators• Results
5References
• References• Contacts
DMC management consulting s.r.o., All rights reserved.
Who We Are
DMC Consulting
DMC Interim Management
DMC Training
DMC management consulting s.r.o., All rights reserved.
Markéta Šimáková
Managing Partner, TWI Certified Trainer (TWI Institute USA), Job Instruction Master Trainer
• Since 1997 in HR consultancy
• From 2002 co-owner of DMC management consulting
• Master Trainer of TWI Job Instruction, Certified Trainer of TWI Job Relations and Job Methods methodology
• Orientation for start-ups of Green Field factories (Philips, TPCA, Honeywell, Futaba)
• Areas of specialization:
• HR and business consultancy
• Training Within Industry
• Green field projects – start-ups
• Outsourcing of HR services
• Education and training programs
• Graduated Sociology and Psychology College, currently studying Andragogicsand HR Management at Philosophical Faculty of Charles’ University
DMC management consulting s.r.o., All rights reserved.
Jitka Tejnorová
Managing Partner, TWI Certified Trainer (TWI Institute USA), Job Instruction Master Trainer
• Active in HR area since 1996
• Co-owner of DMC management consulting since 2002
• Master Trainer of TWI Job Instruction, Certified Trainer of TWI Job Relations and Job Methods methodology
• Oriented on consulting, auditing and educational projects in production, FMCG, pharmaceutical industry and services
• Work experience:
• HR manager in PPF, a.s.
• Member of the Board of Home Credit
• Member of the controlling team of PPF group
• 15 years experience in leadership of consulting projects and education
• Co-author of FunnelMind methodology
DMC management consulting s.r.o., All rights reserved.
DMC management
consulting is from 2010
an exclusive partner of
TWI Institute USA.
We are the only certifiedpartner for the region ofCentral Europe:
Czech Republic, Slovakia, Hungary, Poland, Romania, Bulgaria
DMC management consulting s.r.o., All rights reserved.
TWI – Training Within Industry
BENEFITS OF THE METHODOLOGY
Workstandardization
Increasedproductivity
Faster training
Work safetyImproveddiscipline
Problem solving
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3 TWI Headstones
OperationalExcellence
Job Relations: Creating
culture forchange
Job Methods: Implementimprovedstandards
Job Instruction:
Learnstandard
workoperations
DMC management consulting s.r.o., All rights reserved.
TWI History
40‘s
of20th
centu
ry
USA, 2nd WW. The warproduction lackstrained staff wholeft for thebattlefront. TWI is founded to ensure effectiveproduction.
50‘s
and 6
0‘s
TWI gets to Japan and is used for industry recovery.
Toyota managers perfect their production system over the next 50 years using TWI. Foundation of legendary TPS are laid.
90‘s
An American with Japanese ancestors Patrick Graupp brings improved method back to USA and further improves it.
2001
Foundation of TWI Institute USA (Patrick Graupp and Bob Wrona) www.twi-institute.com
DMC management consulting s.r.o., All rights reserved.
„TWI does NOT change, YOU change…“
Patrick Graupp, TWI Senior Master Trainer
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TWI Institute Central EuropeHistory
2003 2006 2010 2011 2013 2014 2015 2016
DMC meets TPS –green field project TPCA
DMC introduces supervisors‘ academy with TPS elements
TWI Institute Czech Republic.First JI Trainers
Job Relations certification
CertificationJob Methods.TWI usedoutsideproduction –in services
Foundationof TWI Institute Slovakia
2 TWI JI Master Trainers. TWI Institute Poland
TWI Institute CentralEurope.
TWI Institute Hungary
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TWI Institute Central Europe2016
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TWI Institute Central EuropeGrowing „Army of Trainers“
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Strenghtening Key Skills
ATTITUDE
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A Key to Real Work Standardization
• TWI is a dynamic program of practical trainingimproving skills of supervisors and all who lead teams.
• The training is conducted directly at the workplace withimmediate implementation of gained skills.
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Learning by Doing – implementationand usage of new methods
4-Step Process
Small number ofparticipants in traininggroup increases their activeparticipation and maximum success.
Effectiveness and practicalusage of the new skillsimproves when used early after gaining them.
Preparation TrainingImplement-
ationMeasuring
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JOB INSTRUCTION
Effective delegation of work and instructing
Shortened training time
Improved performance thanksto good training
Improved quality
Eliminating production wasteand rework
Less accidents and improved jobsatisfaction
How to quickly teach an operator how to perform a job correctly, safely and conscientiously.
DMC management consulting s.r.o., All rights reserved.
Job InstructionImplementation Steps
START-UP WORKSHOP
4 hrs.
ON-JOB TRAINING
1,5 hr./ participant
COACHES MENTOR-
ING4 hrs.
AUDITS3 hrs.
NEW SYSTEM
PROPOSAL 2-3 hrs.
FINAL WORKSHOP
4 hrs.
TRAINING12 hrs.
• Methodologytraining
• Job breakdownsof particularoperations
• Exercisingtrainingprocess
• Introduction workshop for management
• Practical method demonstra-tion
• Program timeline
• Goal setting• Nomination
of „champion“ responsible for the project at the client
• Mentoring when practicing
• Feedback to methodology usage and fine-tuning
• Breakdown of selected operations and training according to training plan
• Training of coaches in checking the methodology keeping
• How to providefeedback to internal trainers
• Check of correct usage of methodology and standards of prepared instructions
• Targets completion check
• Collecting inputs
• New training system proposal for Final workshop
• Presentation of results for management
• Next steps plan
• Final program evaluation
Total implementation time: 8 – 10 weeks
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Follow-up Activities
After pilot implementation variety of activities to support and leverage the implementation are offered. We recommend to follow with implementation and supervision in furtherproduction lines/operations:
Coaches mentoring and Champion training
•Approx. 16 hours
Job breakdowns standardization
•Support when preparingbreakdowns and check(audit)
Standard training of other groups
•Without coaching, standard 3x4 h class(54.000 Kč)
Train the Trainer
•Training of Championenabling internaltraining of other groups(5x8 hrs, standard price4.900 $, local priceupon agreement withTWI Institute USA)
Implementation of knowledge audits
•And training ofmanagement – approx. 16 hrs
DMC management consulting s.r.o., All rights reserved.
Proven results of JI(CZ/SK clients)
•100% of participants appreciated the approachand oriented fast
100 % orientation in problems
•75 % companies45 % lessdowntimes
•100 % companies30 % less reparation
expenses
•80 % companies (pilot programs)76 % productivity
increase
•100 % companiesmin. 30 % less time
for training
DMC management consulting s.r.o., All rights reserved.
JI – measurable indicators
What is measured: time, quality of instructing, mistakes of trainedoperator
Difference between „ordinary“ training vs. TWI training
Time of training
Number of rejects before and after TWI JI training
Number of rejects „ordinary“ instructing vs. TWI
Effectiveness increase (elimination of overtimes)
Job safety and usage of safety equipment
Confidence and motivation of the trainer
Motivation and feelings of the trained operator
Clearly measurable results = clear return of theinvestment
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Hartmann-Rico, Havlíčkův Brod Production of surgical single-use drapes
Improved effectiveness of training – from original 40h to 20 – 30h (depending on position)
Decrease of complaints – 2012 vs. 2011 – lowered by 50%
Launched job rotation
Standardized job procedures
Brovedani Slovakia, GalantaProduction of metal microcomponents for automotive
Training time shortened by 35% (CNC lathe operator from 6-7 weeks to 4w. After 4 weeks a level B is reached, i.e. the operator is able to independentlyoperate the machine and produce parts (1 operator = 2-3 CNC lathes/shift)
Decreased number of collisons of CNC machines caused by bad adjustmentor the operator
Fluctuation decreased by 5%
TWI motivated people to creativity, engagement – they are bringing improvements, improved teamwork
Results Examples
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Results Examples
Change of production system and people thinking
One-Piece-Flow
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Implementation visualization
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Olympus Medical Products Czech, Přerov Production of optical and digital devices for minimum invasive surgery
Decreasing scrap on pilot line by 46%
Training faster by 22%
Complete training: before TWI: 1 month, after TWI: 1 week
Average scrap rate on operation: before TWI: 4,78%, after TWI: 1,32%
Unified systém of training
Improved communication and cooperation between technicians, internal trainers and operators
Producer of automotive components
Results on pilot line:
Internal complaints: 18 ppm -> 5 ppm
External complaints (0km): 4 ppm -> 0 ppm
Scrap: 1,94% -> 0,98%
HuErr: 0,42% -> 0,14%
Fluctuation 18,6% -> 2,9%
Results Examples
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JOB RELATIONS
Preventing problems from arisingand building loyalty throughdeveloping and maintaining goodrelations.
Method of standardized procedure ofcreating root case analysis whenproblems arise. Includes collectionof facts, weighing possibilities, decision making, acting and resultscheck.
Improved productivity, betterattention, work morale, lessfluctuation
Building positive employee relations, increasing cooperation and motivation, and effectively resolving conflict.
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Proven Results of JR(CZ/SK clients)
• Correct decisions in fundamental problems
• Preventing conflicts – solving problems in time
• Preventing problem repetition
• Support of eliminating unwanted fluctuation
• Strengthening supervisors‘ authority
• Better atmosphere in the team
Prevention of problems, reaction to changes
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Results ExamplesHartmann Rico, Havlíčkův Brod
Production of medical material
less interpersonal conflicts
better communication
better team cooperation
improved morale
increased productivity
better relations among employees
AU Optronics, Trenčín
European Service Center
Improved leaders quality – understanding of supervisor‘s role, improved communication with their subordinates
Problem solving – supervisors come with solutions not problems
Improved cooperation between supervisors
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Results examples
Job Relations (4/6)
Effective communication – information flow (SFM)• Immediate problem solving
• Fast indentification of actual/desired state by indicators
• Better employee engagement and motivation
• Actual results every day – target vs. actual
• Information on changes and planned actions
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Follow-up Activities
TWI JR is a method for changing the way problems inside the company are beingsolved. After finishing the pilot program it is important that all supervisors are trained. Therefore we recommend to nominate internal champion who will long-term lead the training proces:
Training the Champion to beable to provide individualcoaching
•Approx. 16 hrs.
Training other groups
• (without coaching), 3x4 hrs. = 54.000
Train the Trainer
•Training of Champion enablinginternal training of other groups(5x8 hrs, standard price 4.900 $, local price upon conditions ofparticular open course)
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JOB METHODS
Eliminating costs thanks to improved productivity, performance and eliminating semi-finishes
Larger quantity of quality products
Optimum usage of humanresources, machines and materials
Dividing jobs to substantialoperations
Generating ideas for improvementthrough questionning
New methods thanks to eliminating, combining, regroupingand simplifying process steps
Improving the way jobs are done for continuousimprovement
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JM – measurable indicators
• Production and operation tact-time improvement
• Reduction of rework and scrap
• Reduction of manipulation with material and products
• Improvement of ergonomy and job safety
• Employee motivation for change
Clearly measurable results = clear ROI
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Follow-up Activities
After finishing SMED/TWI JM program it is important to fix the new workprocedures. Therefore we recommend the following activities:
Creation of training plan + TWI Job Instruction
training
Creation of all jobinstructions for particularoperation based on thenew work procedure –
approx. 3x 4 hrs. coaching
DMC management consulting s.r.o., All rights reserved.
Results Examples
Tower Automotive, SK Malacky
Automotive components production
Kaizen program – created concept of implementing improvement into companylive
Job Methods applied during Kaizen Events
4/2014 – pilot program – concept definition
7 – 12/2014 – 5x Kaizen Event (3x welding, 2x pressing)
Total annual savings: 72k EUR
AU Optronics, Trenčín
European Service Center
Job Methods implemented as a part of TWI Academy
Increased productivity at selected positions up to 20%
Tact change – proces flow change
.
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Example of JM outputs
• Operation: finalcontrol, paletting, welding tukers
• Improvement: changeof rank of work steps
• Cost: 0 €• Saving: 9.375 €
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Example of JM outputs
• Improvement: cabletesting proces
• Results: • 20% performance
improvement = 2 months of work
• 5 pcs/operator/day• 1,5 operators/year
saved• Improved motivation
and discipline
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And What the People Say?
There's a better atmosphere at work. People have better confidence.
TWI changes corporate culture towards respect to people.
New operators praise the way of training. They feel more relaxed.
Supervisors started to pay more attention to new people.
Processes inside the production simplified, standard work procedures were created.
Our people had fixed habits harming their health. After adaptation of the workplace its ergonomy improved
significantly.
Supervisors solve problems much better thanks to the cards guiding them and helping them to understand the situation.
TWI revealed many gaps we would never be able to find in the process.
To get something you never had,
you have to do something you never did.
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References Job Instruction
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References Job Relations
References Job Methods
DMC management consulting s.r.o., All rights reserved.
Contacts
DMC management consulting s.r.o.
Markéta Šimáková, Jitka Tejnorová
Managing Partner & TWI Master Trainer
Sluštická 1627/14
100 00 Praha 10
Czech Republic
+420 702 093 921
www.dmc-cz.com
www.twi-institute.eu
DMC management consulting s.r.o.
has been examined and found
in conformity with requirements
of the standard ISO 9001:2008.
TWI Institute Slovakia, s.r.o.
Imrich Papp
Consultant & Branch Manager, TWI Certified Trainer
www.twi-institute.eu
Matúškovská 881
924 01 Galanta
Slovak Republic
+421 903 455 225
TWI Institute Poland
Dominika Szymańska
Consultant & TWI Certified Trainer
www.twi-institute.eu
+420 725 731 608
Authorized Partner: Perfectus Group Sp. z o.o.
www.twi-polska.pl
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Thank you for your attention
DMC management consulting s.r.o.
www.dmc-cz.com