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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


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


Who We Are

DMC Consulting

DMC Interim Management

DMC Training


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


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 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


TWI – Training Within Industry

BENEFITS OF THE METHODOLOGY

Workstandardization

Increasedproductivity

Faster training

Work safetyImproveddiscipline

Problem solving


3 TWI Headstones

OperationalExcellence

Job Relations: Creating

culture forchange

Job Methods: Implementimprovedstandards

Job Instruction:

Learnstandard

workoperations


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

http://www.twi-institute.com/


„TWI does NOT change, YOU change…“

Patrick Graupp, TWI Senior Master Trainer


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


TWI Institute Central Europe2016


TWI Institute Central EuropeGrowing „Army of Trainers“


Strenghtening Key Skills

ATTITUDE


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.


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


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.


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


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


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


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


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


Results Examples

Change of production system and people thinking

One-Piece-Flow


Implementation visualization


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


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.


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


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


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



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)


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


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



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


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

.


Example of JM outputs

• Operation: finalcontrol, paletting, welding tukers

• Improvement: changeof rank of work steps

• Cost: 0 €• Saving: 9.375 €


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


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.


References Job Instruction


References Job Relations

References Job Methods


Contacts

DMC management consulting s.r.o.

Markéta Šimáková, Jitka Tejnorová

Managing Partner & TWI Master Trainer

[email protected]

[email protected]

Sluštická 1627/14

100 00 Praha 10

Czech Republic

+420 702 093 921

[email protected]

www.dmc-cz.com

www.twi-institute.eu


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

[email protected]


Matúškovská 881

924 01 Galanta

Slovak Republic

+421 903 455 225

TWI Institute Poland

Dominika Szymańska

Consultant & TWI Certified Trainer

[email protected]


+420 725 731 608

Authorized Partner: Perfectus Group Sp. z o.o.

www.twi-polska.pl

mailto:[email protected]



http://www.dmc-cz.com/

http://www.twi-institute.eu/





http://www.twi-polska.pl/


Thank you for your attention


www.dmc-cz.com

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