Implementing TWI (Training Within Industry) in the CEE Region - the basics of the methodology

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2 Implementing TWI (Training Within Industry) in the CEE Region - the basics of the methodology Jitka Tejnorová TWI Institute Czech Republic 2017

3 Content 1 General 2 Job Instruction 3 Job Relations 4 Job Methods 5 References DMC management consulting Trainers TWI Institute Central Europe TWI philosophy Method description Implementation Follow-up activities Measurable indicators Results Method description Implementation Follow-up activities Results Method description Implementation Follow-up activities Measurable indicators Results References Contacts

4 Who We Are DMC Consulting DMC Training DMC Interim Management

5 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 Andragogics and HR Management at Philosophical Faculty of Charles University

6 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

7 DMC management consulting is from 2010 an exclusive partner of TWI Institute USA. We are the only certified partner for the region of Central Europe: Czech Republic, Slovakia, Hungary, Poland, Romania, Bulgaria

8 TWI Training Within Industry BENEFITS OF THE METHODOLOGY Work standardization Increased productivity Faster training Work safety Improved discipline Problem solving

9 3 TWI Headstones Operational Excellence Job Methods: Implement improved standards Job Relations: Creating culture for change Job Instruction: Learn standard work operations

10 40 s of 20th century 50 s and 60 s 90 s 2001 TWI History USA, 2nd WW. The war production lacks trained staff who left for the battlefront. TWI is founded to ensure effective production. 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. An American with Japanese ancestors Patrick Graupp brings improved method back to USA and further improves it. Foundation of TWI Institute USA (Patrick Graupp and Bob Wrona)

11 TWI does NOT change, YOU change Patrick Graupp, TWI Senior Master Trainer

12 TWI Institute Central Europe History DMC meets TPS green field project TPCA TWI Institute Czech Republic. First JI Trainers Certification Job Methods. TWI used outside production in services 2 TWI JI Master Trainers. TWI Institute Poland DMC introduces supervisors academy with TPS elements Job Relations certification Foundation of TWI Institute Slovakia TWI Institute Central Europe. TWI Institute Hungary

13 TWI Institute Central Europe 2016

14 TWI Institute Central Europe Growing Army of Trainers

15 Strenghtening Key Skills ATTITUDE

16 A Key to Real Work Standardization TWI is a dynamic program of practical training improving skills of supervisors and all who lead teams. The training is conducted directly at the workplace with immediate implementation of gained skills.

17 Learning by Doing implementation and usage of new methods 4-Step Process Preparation Training Implementation Measuring Small number of participants in training group increases their active participation and maximum success. Effectiveness and practical usage of the new skills improves when used early after gaining them.

18 JOB INSTRUCTION How to quickly teach an operator how to perform a job correctly, safely and conscientiously. Effective delegation of work and instructing Shortened training time Improved performance thanks to good training Improved quality Eliminating production waste and rework Less accidents and improved job satisfaction

19 Job Instruction Implementation Steps START-UP WORKSHOP 4 hrs. TRAINING 12 hrs. ON-JOB TRAINING 1,5 hr./ participant COACHES MENTOR- ING 4 hrs. AUDITS 3 hrs. NEW SYSTEM PROPOSAL 2-3 hrs. FINAL WORKSHOP 4 hrs. Introduction workshop for management Practical method demonstration Program timeline Goal setting Nomination of champion responsible for the project at the client Methodology training Job breakdowns of particular operations Exercising training process 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 provide feedback 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

20 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 further production lines/operations: Coaches mentoring and Champion training Approx. 16 hours Job breakdowns standardization Support when preparing breakdowns and check (audit) Standard training of other groups Without coaching, standard 3x4 h class ( Kč) Train the Trainer Training of Champion enabling internal training of other groups (5x8 hrs, standard price $, local price upon agreement with TWI Institute USA) Implementation of knowledge audits And training of management approx. 16 hrs

21 Proven results of JI (CZ/SK clients) 100 % orientation in problems 100% of participants appreciated the approach and oriented fast 45 % less downtimes 75 % companies 30 % less reparation expenses 100 % companies 76 % productivity increase 80 % companies (pilot programs) min. 30 % less time for training 100 % companies

22 JI measurable indicators What is measured: time, quality of instructing, mistakes of trained operator 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 the investment

23 Results Examples 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 lowered by 50% Launched job rotation Standardized job procedures Brovedani Slovakia, Galanta Production 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 independently operate the machine and produce parts (1 operator = 2-3 CNC lathes/shift) Decreased number of collisons of CNC machines caused by bad adjustment or the operator Fluctuation decreased by 5% TWI motivated people to creativity, engagement they are bringing improvements, improved teamwork

24 Results Examples Change of production system and people thinking One-Piece-Flow

25 Implementation visualization

26 Results Examples 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%

27 JOB RELATIONS Building positive employee relations, increasing cooperation and motivation, and effectively resolving conflict. Preventing problems from arising and building loyalty through developing and maintaining good relations. Method of standardized procedure of creating root case analysis when problems arise. Includes collection of facts, weighing possibilities, decision making, acting and results check. Improved productivity, better attention, work morale, less fluctuation

28 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

29 Results Examples Hartmann 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

30 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

31 Follow-up Activities TWI JR is a method for changing the way problems inside the company are being solved. After finishing the pilot program it is important that all supervisors are trained. Therefore we recommend to nominate internal champion who will longterm lead the training proces: Training the Champion to be able to provide individual coaching Approx. 16 hrs. Training other groups (without coaching), 3x4 hrs. = Train the Trainer Training of Champion enabling internal training of other groups (5x8 hrs, standard price $, local price upon conditions of particular open course)

32 JOB METHODS Improving the way jobs are done for continuous improvement Eliminating costs thanks to improved productivity, performance and eliminating semifinishes Larger quantity of quality products Optimum usage of human resources, machines and materials Dividing jobs to substantial operations Generating ideas for improvement through questionning New methods thanks to eliminating, combining, regrouping and simplifying process steps

33 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

34 Follow-up Activities After finishing SMED/TWI JM program it is important to fix the new work procedures. Therefore we recommend the following activities: Creation of training plan + TWI Job Instruction training Creation of all job instructions for particular operation based on the new work procedure approx. 3x 4 hrs. coaching

35 Results Examples Tower Automotive, SK Malacky Automotive components production Kaizen program created concept of implementing improvement into company live 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.

36 Example of JM outputs Operation: final control, paletting, welding tukers Improvement: change of rank of work steps Cost: 0 Saving: 9.375

37 Example of JM outputs Improvement: cable testing proces Results: 20% performance improvement = 2 months of work 5 pcs/operator/day 1,5 operators/year saved Improved motivation and discipline

38 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.

39 To get something you never had, you have to do something you never did.

40 References Job Instruction

41 References Job Relations References Job Methods

42 Contacts DMC management consulting s.r.o. Markéta Šimáková, Jitka Tejnorová Managing Partner & TWI Master Trainer Sluštická 1627/ Praha 10 Czech Republic TWI Institute Slovakia, s.r.o. Imrich Papp Consultant & Branch Manager, TWI Certified Trainer Matúškovská Galanta Slovak Republic DMC management consulting s.r.o. has been examined and found in conformity with requirements of the standard ISO 9001:2008. TWI Institute Poland Dominika Szymańska Consultant & TWI Certified Trainer Authorized Partner: Perfectus Group Sp. z o.o.

43 Thank you for your attention DMC management consulting s.r.o.