Why and How to Do TWI Job Instruction

Training Within Industry: Job Instructions (JI) - Preview

• Purpose of TWI Job Instruction Training:

  • Developed to equip supervisors with effective instructing skills.
  • Contrasts ISO 9001 standards by focusing on the "how-to" rather than general guidelines.
  • Aims to ensure competence in job execution through structured training.

• Key Objectives of Job Instruction Training:

  • Enable correct, quick, and conscientious job execution.
  • Address root causes by standardizing training methods.
  • Optimize allocation of training resources and time.

• Methodology of Training:

  • Emphasizes step-by-step instruction with a focus on demonstrating and explaining tasks.
  • Involves a seven-step process for effective training sessions.
  • Advocates for consistent application through the use of training cards as a guide.

• Challenges in Training Implementation:

  • Acknowledges the prevalent need for better training within companies despite insufficient action taken to address it.

Source:

 How To Perform Training Within Industry Job Instruction - Preview

• Focus on TWI Job Instructions: The session delves into the effectiveness of TWI job instructions compared to traditional methods, emphasizing their efficiency in training.
• Key Components: It highlights two crucial aspects: creating a job breakdown sheet and the four-step training process: preparation, presentation, application, and testing, aligned with PDCA (Plan-Do-Check-Act).
• Practical Implementation: Using an underwriter's case as an example, the process of creating a job breakdown sheet is demonstrated, emphasizing identifying key points and error prevention.
• Segmented Training Approach: Advocates for breaking training into teachable segments to prevent overwhelming learners, drawing from an example of dividing assembly training into manageable parts for effective learning.
• Benefits and Sustainability: Shows significant reductions in word count (80%) for clearer, user-friendly instructions. It also highlights statistics indicating a 25% reduction in training time and emphasizes the sustainability and benefits of TWI training in driving quality, productivity, and leadership development within an organization.

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 You might be wondering, why have I not heard much about this methodology although it's been around for a long time...  History helps you understand.

A Brief History of T.W.I. (Training Within Industry): The Post War Era

• Post-War Era of TWI:

  • After World War II, TWI persisted for a few years before fading.
  • US occupation in Japan aimed to revamp industrial methods, identifying a lack of suitable training for supervisors and workers.
  • Recognizing the need for training due to war's impact on Japan's economy, the US brought TWI to Japan, fostering its growth and integration into Japanese culture.

• TWI's Impact in Japan:

  • By 1966, over 1 million managers and supervisors in Japan were trained in TWI.
  • TWI became integral to Japanese practices, influencing systems like Toyota Production System (TPS) and fostering cultural change through job instruction and methods.

• TWI's Influence Beyond Japan:

  • TWI extended globally post-war, adopted by various countries including Great Britain, European nations, New Zealand, and others in diverse industries from railways to banking.

• Challenges to TWI's Sustainability:

  • Alterations to the original TWI program, lack of proper management support, and the absence of a governing body led to TWI's decline by the 1990s in the US and parts of Europe.

• Importance and Lessons from TWI:

  • TWI's legacy endures in lean methodologies like error-proofing, standardization, teamwork promotion, and the need for a supportive infrastructure for sustainable training programs.

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And seeing the process in practice will help you understand the benefits and how it works better than "traditional" training.

 Training Within Industry 1944 Video

• Introduction to a new drill press operator, Mary, by Fred, showcasing initial guidance and safety measures.
• Fred's initial instructions lack precision, leading to errors in the drilling process by Mary.
• Fred realizes the necessity for detailed, step-by-step instructions and individualized teaching methods.
• The training methodology evolves to include explicit instructions, practical demonstration, hands-on practice, and comprehensive understanding of the task's reasons and implications.
• The significance of meticulous instruction is highlighted for effective skill acquisition, emphasizing its long-term benefits in time, cost, and quality of work.

and now you're ready to understand...

How To Perform Training Within Industry Job Instruction

• Overview: The video focuses on the Training Within Industry (TWI) job instruction, emphasizing two crucial aspects: the development of a job breakdown sheet and the teaching process.
• Learning objectives: Understanding the four-step training process, creating an effective job breakdown sheet, implementing the basic teaching pattern, and sustaining the benefits of TWI job instructions.
• Seven-step training process: Forms the core of the teaching process and represents steps two and three of the overall process.
• Emphasis on synergy: Stressing the interconnectedness of the job breakdown sheet and the teaching pattern, highlighting that using them together is vital for effective training.
• Importance of participation: The video emphasizes that the session offers an overview rather than a complete training and underscores the necessity of hands-on, participative learning for a comprehensive understanding.

Seeing an example of how to develop and use a Job Breakdown Sheet will help you...

Introduction and Overview:

• Emphasis on the pivotal role of job breakdown within the TWI methodology for efficient training.
• Highlighting job breakdown as the cornerstone of TWI, labeled the "secret sauce" for effective job training.
• Practical demonstration using a fire underwriters knot to elucidate the step-by-step breakdown process.
• Explanation of the four-step approach within TWI modules, directly applicable to job breakdown strategies.

• Four-Step Approach Overview:

  • Emphasizes the fundamental four-step approach of Training Within Industry (TWI).
  • Step 1: Prepare the worker to learn, highlighting the importance of laying the groundwork for effective training.

• Job Breakdown Importance:

  • Illustrates the significance of a job breakdown within TWI methodology.
  • Describes it as the 'secret sauce' of TWI, diving deeper into the breakdown process.

• Step 1 - Prepare the Worker to Learn:

  • Discusses the significance of preparing the worker for effective learning.
  • Acknowledges the potential oversight of essential steps in training, highlighting the role of job breakdown as a cue card for trainers.

• Job Breakdown Example - Fire Underwriters Knot:

  • Walks through an example of breaking down the process of tying a fire underwriters knot.
  • Demonstrates the breakdown into steps, key points, reasons, and critical aspects, using 'untwist and straighten' as the initial step.

• Key Points and Reasons in Job Breakdown:

  • Emphasizes the importance of identifying key points and understanding the reasons behind each step in the breakdown.
  • Discusses how these elements contribute to effective training and comprehension.

• Identifying Critical Aspects:

  • Explains the process of identifying critical aspects in a job breakdown.
  • Stresses the significance of recognizing what can make or break the job, endanger the worker, or simplify the task.

• Importance of 'Why' in Training:

  • Highlights the value of understanding the 'why' behind each step in the job breakdown.
  • Stresses that comprehending the rationale aids in better understanding and retention during training.

• Incorporating Expertise into Job Breakdown:

  • Discusses the involvement of experts in creating a job breakdown.
  • Emphasizes the need to watch experts perform tasks, noting the importance of their insights in crafting effective breakdowns.

• Documentation and Training Matrix:

  • Advocates for documenting training, especially within ISO or quality programs.
  • Stresses the significance of creating sign-up sheets and training matrices to track and certify completed training.

• Repetition and Training Efficiency:

  • Discusses the efficiency of short, repetitive training sessions within TWI.
  • Highlights that while the entire breakdown may take 10-15 minutes, the repetition aids in better retention and understanding.

And now you can understand...

The 4-Step Job Instruction Teaching Pattern:

• Preparation: The trainer readies the worker and the workspace, establishing a comfortable learning environment and putting the trainee at ease.
• Presentation: Methodically demonstrating the job step-by-step, breaking it down into manageable tasks, and repeating until understood.
• Performance Trial: The trainee performs the job under supervision, receiving corrections and explanations for any mistakes made.
• Follow-up: After ensuring comprehension, the trainee works independently but with support available, gradually reducing instruction as confidence grows.

and you will be ready to...

How to Train People Effectively

• Effective Training: Explained as 'I do, we do, you do.'
• 'I do' Phase: Demonstrating the task while narrating the thought process behind each action, allowing participants to observe and understand the reasoning.
• 'We do' Stage: Participants perform the task while the trainer observes, providing immediate feedback, encouragement, and clearing up any confusion or hesitation.
• 'You do' Phase: Individuals perform the task independently, receiving personalized feedback from the trainer to achieve mastery.
• Importance: Highlighted significance of each step for comprehensive training; missing any stage undermines effectiveness.

Course Forward:

How do you like this methodology?  Would you like to see it in practice, practice yourself and teach it to others?

Please visit our free mini-course on TWI and Job Instruction training, which includes an opportunity to participate in a group workshop using a Simulation exercise to learn and practice TWI Job Instruction.

Here is the link: https://www.beltcourse.com/job-instruction-trainer

And consider sharing it with others who might be interested!