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Tom Albrecht & Colin Rusel Aluminum Trailer Company
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TWI & Lean HR Summit
Hyatt Regency Riverwalk
San Antonio, TX
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Who are we?
VS1 Trailer
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$4 -10K
VS2 Trailer
$10 -40K
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VS3 Trailer
$40 - 400K VS6 Trailer
Why are we here?
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The ATC Experiment
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True North
Respect for People
100% on time delivery
15% productivity improvement
100% value added
Zero defects
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TWI – JR 1st Iteration
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Lean Management System
Courtesy of the Murli Group
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TWI – JR 2nd Iteration
TWI Vision
Knowledge of work
Knowledge of responsibilities
Instructing
Leading
Improving
12 TWI Participant Guide - Job Instruction 10-hour Workshop
Leadership Initial State
Knowledge of work
Knowledge of responsibilities
Instructing Leading
Improving
50% Focus
5% Focus
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How we build great trailers
Safety, quality and cost (productivity)
• Rework • Trouble shooting • Fire fighting
45% Focus
General production work
TWI Leadership Goal 2013
Knowledge of work
Knowledge of responsibilities
Instructing
Leading
Improving 50% Focus
8.3% Focus
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25% Focus
• Rework • Trouble shooting • Fire fighting
8.3% Focus
8.3% Focus
25% Focus
General Production work
16.6% Focus
Knowledge of work
Knowledge of responsibilities
Instructing
Leading
Improving
50% Focus
16.6% Focus
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16.6% Focus
TWI Goal for Plant 2
Lean Management System
Knowledge of work Knowledge of responsibilities
Instructing for Skills
Leading
Improving
100% Focus
Safety, Quality & Cost
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Problem Solving /Coaching
Job Relations & LMS
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Everybody, everywhere, coming together to solve problems.
Three parts and how each influences Job Relations
1. LMS - structure that makes a difference
2. Standard Work
3. The Psychology of Optimal Experience
LMS
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Part 1. The Lean Management System
A structure for teamwork and communication
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TaskTime Sheets
20 Forced us to be accountable and transparent
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A Lean Management System
Andon…
…forced us to communicate
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A Lean Management System
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Standard Work
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Part 2. Operational Standard Work
Quality Standard
Work Instruction
Standard Work
Job Instruction 29
2016 Standard Work
Work Instructions
Work Instruction
Quality Standard
Standard Work
Job Instruction 30
Current Documentation
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Work Instruction
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One best way we know now….
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38 22 Minute Gap The one best way we know now…
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98.82
90.55
96.12
88.32
85.52
82.98
84.68
78.40
70.00
75.00
80.00
85.00
90.00
95.00
100.00
105.00
110.00
Tota
l Min
ute
s
OUT Station 1 (Kyle) / 6 Weeks - September, 29- October 15, 2015
Cycle time
SW Rev 2.0
Kyle new to station SW Rev 1.0
Cross training
Coaching and new SW implemented after complete takt interval time test by Eric and Tom on 10/08/15.
SW Rev 3.0 New current state 10/15/15
Performance & Standard Work
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Gaps
--------- Defects after electrical skills JI training --------- Defects after cross training new Employee 1 & 2
Emp. #1 Emp. #2
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The Need for Work Instruction
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Visual Standard Work
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Part 3. The Zone: Job Relations & Csikszentmihalyi
… Golf, is "a game that can't be won, only played." Link
Another Look at Flow
48 Csikszentmihalyi, M. (1990). Flow: The Psychology of Optimal Experience. New York: Harper and Row
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-Sense of adequacy
-A clear objective
-Concentration
-Immediate feedback
-Apparently effortless involvement
-Removal of concerns or distractions
-A sense of control
-Concern for Self disappears
-Awareness of time is altered
Challenge Vs Skill
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WHY TWI
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Everybody, everywhere,
coming together
to solve problems.
Job Relations and PDCA
Link
12 Mo - Open Utility Frame Table
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Improved Capacity
Photo Here
Next Steps?
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Everybody, everywhere, coming together to solve problems.
Tom Albrecht & Colin Rusel Aluminum Trailer Company
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References: Csikszentmihalyi, M. (1990). Flow: The Psychology of Optimal Experience. New York: Harper and Row
TWI Participant Guide Job Instruction 10-hour Workshop
Murli Group
Dreamworks – The Legend of Bagger Vance
