Webinar February 25, 2010 Presenters: Steve Grossman and Sam Wagner

Outline for today 1. Introductions 2. Training Within Industry 3. How does TWI Support Lean ? 4. What is a TWI Champion ? 5. Why is the TWI Champions Critical to Success?

Outline for today 6. How are TWI Champions Created? 7. What are the Key Tasks of the TWI Champions? 8. Donnelly Manufacturing 9. Measuring Results 10. Q & A

1. Introductions Steve Grossman Director of the TWI Institute Sam Wagner Director of Advanced Manufacturing Donnelly Custom Manufacturing

2. What is Training Within Industry (TWI)? Standardized programs addressing the essential skills needed by supervisors, team leaders, and anyone leading others. The program is composed of four skill-based modules:  Job Relations (JR)  Job Instruction (JI)  Job Methods (JM)  Job Safety (JS)

3. How does TWI Support Lean? TWI is more than the link that unites lean practice with the training to sustain it. Actually, it is more like a series of links that both hold the effort together and communicate the key messages. It is the DNA of Lean

TWI Is the Mortar the Holds the House of Lean Together

4. Who are the TWI Champions? Corporate Site Manager Gemba TWI Champion at the Gemba TWI Champion Site Manager TWI Corporate Champion

Who are the Management TWI Champions? The CEOs and managers who effectively communicate the importance of TWI and dedicate the critical resources. TWI Corporate Champion TWI Champion Site Manager TWI Champion at the Gemba

Who are the TWI Champions at the Gemba? The Leaders and Supervisors who direct the work of others in the workplace and who are provided with the training and time to implement TWI. TWI Corporate Champion TWI Champion Site Manager TWI Champion at the Gemba

5. Why is the TWI Champion Critical to Success ? No Champion = No formal structure No fully committed resources No clear direction No Certified J trainers

6. TWI Champions: How are they Created? Initial TWI ten hour training New classification Job Posting Screening for skills and abilities Commitment by management to dedicate resources (time and training) Champions may become certified in selected TWI programs

7.What are the Key Tasks of the TWI Champion? Identification of priorities with Management Creating JIBS (JI) Focus efforts Establish Training Schedules Audit results

Provide Coaching Run the Steering Committee Follow-up on training (both 10-hour classes and actual instruction of jobs) Audit operator instruction and skill …………………………………..

8. Donnelly Manufacturing

Load ‘em up (the shells) Light ‘em up (the fuses) Get Out of the Way Oooh and Ahhh!!

Load ‘em up! 1. Define your objectives and link to your key business needs / critical success factors JR: leadership training for shop floor associates; address “fairness” and turnover JI: train better and faster for new associates and setups; improve quality JM: engage associates; improve value- add per employee, safety, quality 2. Involve Managers Observe training Develop training plan 3. Develop measurements 4. Build into performance appraisals

Light the Fuses 1. Start the training Go for density 2. Coach Managers / Supervisors how to encourage (and not discourage) Carry and refer to the card Look for ways to use it Don’t accept when it should be used and isn’t If too late, describe how it could have helped 3. Post visual measures 4. Broadcast early successes

Get Out of the Way 1. Let your Supervisors own it, but strongly support: Training plan Visuals Core concepts 2. Let TWI adapt to your environment Supervisory training JI breakdowns as a training tool JI training delivery versus breakdown development JM breakdowns 3. Track who is using it – and who’s not

Oooh and Ahhhh! 1.Encourage ongoing Training and learning Read books & articles Blogs, webcasts Peer councils Seminars and conferences TWI Summit 3. Celebrate 4. Brag about your team!!!

Oooh and Ahhh Get out of the way Light ‘em up Load ‘em up

9. Measuring Results Exemplary TWI Companies Have Documented Improved Profits Through: Customer Quality PPM Improvements Training Time Reductions Rework Reductions Defect Reductions Setup Time Reductions Reduced Employee Turnover Reduced Absenteeism Takt Time Reduction Lead Time Reductions Incident and Accident Reductions

10. Questions ?

Thank You! TWI Institute The TWI Institute in Partnership with