developing job breakdown sheets according twi methodology
TRANSCRIPT
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Developing Job Breakdown Sheets according the TWI (Training Within Industry) methodology
Ho Chi Minh City, 06/09/16 © Michele Lauriero, 2016
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TWI – Training Within IndustryHistory of the TWI methodology:• Developed in 1940’s in U.S.A. to quickly develop and
re-train unskilled work force in the industry
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• TWI gave excellent results. All companies applied it reported: increased productivity (> 25%) reduced training time (> 25%)
• After the war USA exported the TWI methodology in Japan to help the industrial rebuilding
• The TWI methodology was adopted by Toyota, improved and become part of the T.P.S.
• Today TWI is part of the “lean management” tools used worldwide to standardize the work, standardize the training of workers and quickly raise skills on production floors.
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What is TWI?The Training Within Industry TWI program is all about training and coaching supervisors (“train the trainers”) giving them:
1. Knowledge of the work2. Knowledge of the responsibilities of the job
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The 3 J’s programJI — Job Instruction Training — to train supervisors how to train employees to quickly learn and consistently remember how to do any job correctly and safely.
JM — Job Methods Training — to train supervisors how to lead teams to quickly improve job methods to produce more in less time, making the best use of resources.
JR — Job Relations Training — to train supervisors how to lead people in ways that prevent and quickly resolve problems.
The J.B.S. are developed to support this phase of program.
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JBS
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The J.B.S.• Synthetic way to standardize the work optimizing the skill
transfer to new employees
• It focus on main points and not list each single detailed motion
• It is not a “Complete Instructions Manual” for the job that can be handed to the employees
• The main purpose is to help the instructor organize the job in their mind and determine the best way to convey this knowledge to the employee
• It’s written by the instructor as a tool “from us to our-self”
• They are organizing tools for the trainer, not for handing over to the learner
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What is inside a JBS• Complete information about the task, task number, parts and
components used, tools, material, safety equipment, etc…
• Major Steps: As it says – only major steps Always start with a “verb” Single short sentences
• Key points: Safety Quality Tip and tricks (knowledge based on experience)
• Reasons
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First part – Task information
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Second part – Job breakdown
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MAJOR STEPS
Any logical segment of the operation that helps advance the job or adds value to the product.
• List all the steps in the actual sequence performed usually
• Focus on the operator point of view
• Major steps is not a full description of motions to be done
Example:Screw the winch flange on deck Yes – is a M.S.
Get screw driver from the toolbox No - isn’t a M.S.
KEY POINTSAny important issue related to quality, safety and information to know to make the job better.Each M.S. may have more than one K.P.
Typical key points are info that:
1. Make the job 2. Break the job 2. Injure the worker 3. Make the work easier
Use graphic symbol to make the JBS visual:
REASONThere is a difference between child education and adult education.Most of the adults while learning need to know the reason – WHY?
• Quality precautions• Waste prevention• Health precautions• How the final result
should look like• How match one part to
the other
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Third part – Pictures / Training aid
USE PICTURE FOR EFFICIENT VISUAL
REPRESENTATION OF KEY POINTS
Check pressure. The right value must be between 0.5 and 2.4 bar
What’s better?
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Practical example – Replace a wheel
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• Efficient way to standardize the work• Rely on real technical document instead of
memory• Strong tool for a fast and effective training• Starting point for a real “kaizen” on the floor• Give strong value to the “supervisors” (team
leaders)
Benefit of a well done set of JSBs