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Training Within Industry
This Missing Link for Lean Produces Sustainable Improvement Over Time
Workplace Symptoms That Show a Need for TWI:
- Inconsistent production results
- Excessive rework
- High employee turnover
- Low employee moral
Hire, Train & Retain Great Employees
 To be competitive in today’s global market, it is more important than ever to hire, train and retain great employees. TechHelp has helped hundreds of Idaho companies train front line workers in the disciplines of advanced manufacturing. Businesses adopting Training Within Industry (TWI) have consistently increased productivity, reduced training times and improved morale.
Training Within Industry is a dynamic program that uses a learn-by-doing approach to teach essential skills for supervisors and team leaders from all industries.
TWI is composed of three programs: Job Relations, Job Instruction and Job Methods. These programs work together to help supervisors build and maintain positive employee relations, train workers to quickly remember how to perform jobs correctly and safely & conscientiously improve the ways in which jobs are done.
What Does it Do?
Training Within Industry quickly and effectively trains supervisors in:
- Skills in Improving Methods - Job Methods (JM) teaches the skills needed to analyze jobs to make the best use of resources.
- Skills in Leading - Job Relations (JR) teaches the skills needed to evaluate and take action to handle and prevent people problems.
- Skills in Instructing - Job Instruction (JI) teaches the skills needed to quickly develop a well trained work force.
TWI Also:
- Reduces training time.
- Standardizes training.
- Increases productivity.
- Improves morale.
What Does it Solve?
- Effects of poor training - mistakes, poor quality, rework, scrap...
- Inconsistent handling of employee issues - uses 4 step JAR method to ensure all issues are handled in a common way
- Long learning curve for new supervisors - Gets supervisors up to speed fast
History
TWI was developed in the U.S. during WWII to train replacements of an industrial workforce off fighting a war. It provided rapid and consistent training and is recognized as part of what helped the Allied forces secure victory as they boosted industrial production and out-produced the enemy. TWI was an unqualified success.
Expansion in Japan
TWI was introduced in Japan during post-war rebuilding. It is still in widespread use in Japan; most notably at Toyota as part of the Toyota Production System (TPS). It is a foundation to Toyota's success in continuous improvement, and more importantly, in its ability to sustain those improvements.
 Emerging Movement
A prosperous post-war America gradually lost interest in TWI. But todays competitive global marketplace is forcing U.S. managers to adopt the best tools available to hire, train & retain great workers. In what has been described as a "movement," Lean enterprises nationwide are increasingly turning to TWI as a means to emulate Toyota's ability to sustain improvements and achieve standard work. Industries such as health care, construction, and manufacturing are reaping modern day benefits from this proven and recently revived program.
Who Will it help?
- Anyone in a position where they direct and plan the work of others.
- Any company adding workers
Impact of TWi
1,750,650 people trained in 16,511 plants and unions
Of 600 companies monitored:
- 86% increased production by at least 25%
- 100% reduced training time by 25% or more
- 88% reduced labor hours by at least 25%
- 55% reduced scrap by at least 25%
- 100% reduced grievances by more than 25%
Why TechHelp?
- TechHelp offers "one stop shopping" that delivers TWI as part of a Lean Transformation.
- With its experienced specialists, University partnerships and affiliation with the national Manufacturing Extension Partnership - TechHelp brings world class expertise to your local area.
- TechHelp provides high quality programs at affordable prices
TechHelp Expertise
David O'Connell, of TechHelp and Idaho State University, has taken a special interest in TWI and made it one of his primary areas of practice. As an accomplished Lean Practitioner, David has seen the special role TWI can play in creating a workforce that is well trained, cross-trained, highly motivated and effective.
If you are interested in hiring, training and retaining great employees, contact David today:
 David O'Connell
Manufacturing Specialist
Idaho State University
1651 Alvin Ricken Drive
Pocatello, ID 83201
Phone: 208-282-3928
Cell Phone: 208-589-5567
ocondavi@isu.edu
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