TWI Job Instruction (TWI-JI) develops your front-line leaders’ capability to stabilise processes and work methods (standardisation).
It helps connect the written work standard with the actual practice on the shop floor and teaches the technique of delivering effective on-the-job training that ensures people reliably perform a task exactly the way it should be done to get consistently good results.
The ability to perform work consistently over time, and across multiple workers and shifts, is essential to achieving stable, reliable process performance. It is also critical as an enabler of rapid process improvement through Kaizen, Lean Manufacturing or Service, and Operations Excellence programs.
By ensuring methods are reliably performed in the same way, your supervisors will be able to
dramatically reduce on-boarding and training times,
improve reliability and on-time delivery
increase flexibility and cover through effective cross-training,
squeeze rejects and rework,
prevent accidents and reduce near-misses,
boost staff engagement.
Without effective standardisation using TWI JI, operations leaders will experience high variability in process performance, including frequent operator mistakes, unreliable on-time-delivery performance, fluctuations in output, productivity difference across operators, shifts and machines, machine performance and reliability issues and high levels of staff turnover or absenteeism.
Job Instruction develops hands-on skills in identifying the ‘one best way’ our SMEs (subject matter experts) know how to perform the work and passing on this method through simple, reliable and effective on-the-job instruction to new and experienced operators. Supervisors and Team Leaders also learn how to follow up effectively with the workers to ensure the standard method ‘sticks’ and is applied consistently by everyone until a new, better method has been developed by the operations team.
Job Instruction skills developed through the Supervisor Academy TWI JI program include:
observing the work method of the best workers and developing the new work standard using the Job Instruction Breakdown technique
testing and validating the new standard work
identifying and anticipating training needs, as well as planning and executing job-skills training using the TWI JI training timetable
training new and experienced workers using the time-proven TWI JI 4 Step method
planning and executing effective follow-up through method audits and effective visual management
Our experienced Supervisor Academy coaches accompany you and your team from training through full deployment to reinforce TWI JI skills, provide guidance on how and where to apply them to extract rapid Return on Training Investment (ROTI) and how to ensure sustainability of your standardisation efforts.