Building a Global Learning Organization Using TWI to Succeed with Strategic Workforce Expansion in the LEGO Group

LAYING THE GROUNDWORK

Setting the Course
Introduction
The Need for Change
Strategic Capability Building
     Building the Molders of Tomorrow
     "And Notice Nothing Else but the Language and the Local Temperature"
Growth Creates Need for Training
     Laying the Foundation for a Global Learning Center

Preparing for the Global Pilot Project
Introduction
Pilot Project Team
     Sponsor
     Steering Team
     Project Manager
     Key Stakeholders
     The Pilot Project Team
          Learning Center Track
          Operations Track
Pilot Project Description
     Background
     Objective
Needs Analysis
     Visit to LEGO Operations Mexico
     The Hungarian Phone Calls
     Discussions in Denmark
     Summary of Local Visits
Selecting the Pilot Case

Setting the Foundations for Moving Forward
Introduction
First Draft of the Training Organization
Choosing the Training Within Industry Program: Why Job Instruction?
The Link between Job Instruction and Lean
     A Strong Lean Foundation
The Standardized Work Development Model
     Prework
     Establishment of Global Trainer Team
     Development of Global Training Standards
     Training Locals in the New Standard
     Establishment of a Follow-Up and Process Confirmation Process
     Establishment of Continuous Improvement Structure

THE GLOBAL PILOT PROJECT

Testing the Global LEGO Training Organization and TWI JI
Introduction
Reactions to the Change
Learning How to Make Job Breakdowns
     Facilitating the Development of Important Steps
     Facilitating the Development of Key Points
     Finding Key Points: A Great Learning Experience
First Workshop: Hungary
The Workshops
Cultural Introduction
     Social Event
"Homework" Periods

The Workshops
Introduction
Workshop 1: Mexico
     Operations Track (Functional Area Master Trainers and Global Job Trainers)
     Standardized Work Chart
     TWI Job Instruction 10-Hour Class
     Videoconference Wrap-Up
Workshop 2: Denmark
     The Whole Team: Cultural Training
     TWI Introduction to Stakeholders
     Learning Center Track
     Operations Track
Workshop 3: Hungary
     Coaching the TWI Job Instruction Four-Step Method
     The Whole Team
     Learning Center Track
     Operations Track
Workshop 4: Denmark
     The Whole Team
     Sudden Realization
     Learning Center Track
     Operations Track (Global Job Trainers)
     Testing the Job Breakdown with Relevant Stakeholders
Workshop 5: Mexico
     The Whole Team
     Learning Center Track
     Operations Track (Global Job Trainers)
     Operations Track (Functional Area Master Trainers)
Workshop 6: Hungary
Approval of the Pilot Project
From Global Pilot Project to Local Anchoring
     Different Needs
     Molding Hungary
     Molding Mexico
     Molding Denmark
     General Notes on the Local Implementations

CREATING THE GLOBAL LEGO TRAINING ORGANIZATION

Building the Organization
Introduction
Roles in the Training Organization
     Being a Trainer Is a Role—Not a Position
     Trainer Roles and Responsibilities
     Who Wants to Be a Trainer?
Building Up the Training Organization: Selection Process
     How to Spot Trainer Talents in the Organization
          Cognitive Skills
          Communication Skills
          Social Attitude
          Confidence and Leadership
          Work Attitude
          Questioning Nature
     The Interview
     Practical Exercise 1
     Practical Exercise 2
Onboarding Process
Development Process
     Job Instruction
     Training and Learning Skills Course
          Module 1: Adult Learning
          Module 2: DiSC Introduction
          Module 3: Communication and Feedback (4 Hours)
          Module 4: Training Challenges
     Building Cultural Competencies
     English Skills
Evaluation Process
Learning Points: Building the Training Organization

Learning Tools and Methodologies
Introduction
Competency Overview and Learning Objectives
     Learning Objectives
Skills Matrix
     Helping Questions
Individual Training Plan
Evaluation
Learning Methodologies
     On-the-Job Training: Job Instruction
     Challenges to Shop Floor Training
     Classroom Training
          Classroom Training in Material Knowledge
     e-Learning

ROLLOUT

Sustaining the Effort and Growing the Future
From Pilot Project to Program Management
Job Relations Implementation
Rollout in Asia
     Insight from the Mexico Experience
     Training Approach

In Their Own Words: Case Studies from the Implementation
Introduction
Ericka Hernandez: New to the Learning Center in Mexico
Fruzsina Veress: Leadership and Implementation in Hungary
Pavel Kroupa: Key Roles and Collaboration in TWI Implementation in the Czech Republic
     Collaboration with Top Management
     Collaboration with Production Management
Ole Therkelsen: Mold Manufacturing in Mexico

Index

Biography

Patrick Graupp, Gitte Jakobsen, John Vellema

LEGO has been a household name all of my life and I was aware that they had a strong people-focused culture and adopted Lean methods. This book, written with LEGO insiders, is a stunning example of the discipline and commitment needed to develop people as masters of their crafts through the only way people learn—repetitive, deliberate practice.
—Jeffrey K. Liker, Professor, University of Michigan; and Shingo Prize-winning author of The Toyota Way

Few books, if any in the Lean area since the NUMMI era, have gone into such depth on what it takes to integrate and unify across cultures. The book will become a standard guide not only to TWI implementation, but to the wider challenge of cross-functional and cross-cultural integration.
—John Bicheno, Founder of MSc in Lean Enterprise at The University of Buckingham

While TWI has made a significant comeback in recent years as the underpinning of the Toyota Production System’s foundation for continuous improvement and standard work, the ability to make it an integrated and sustainable system of developing people with a highly productive capability to solve problems while continually learning has remained elusive to most organizations. The book describes in detail how LEGO achieve this culture through a strategic and deliberate plan to develop and deploy a global system of organizational training using TWI as its foundation.
—Jim Huntzinger, President/Founder, Lean Frontiers