1st Edition

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

    237 Pages 31 B/W Illustrations
    by Productivity Press

    237 Pages
    by Productivity Press

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    Building a Global Learning Organization: Using TWI to Succeed with Strategic Workforce Expansion in the LEGO® Group describes how a multinational company developed a global structure for learning based on the TWI (Training Within Industry) program to create and sustain standardized work across multiple language and cultural platforms. In this book, Shingo Prize-winning author Patrick Graupp collaborates with two practitioners who performed the planning and implementation of the LEGO Group’s worldwide Learning Organization.

    The book outlines the organizational and planning models used by the LEGO Group to create the internal ability to give and receive tacit skills and knowledge. Describing how and why TWI is used as the foundation for success in knowledge transfer across diverse languages and cultures, it provides step-by-step guidance on how to establish a solid organizational foundation for your own Learning Organization.

    Providing expert insight into the work of culture change, the book explains how to work with people to create motivation for moving to a new system of learning. It details the critical elements that made the implementation at the LEGO Group a success, identifies the stumbling blocks they encountered along the way, and explains how they were overcome. Case studies describe in detail what these efforts looked and felt like in actual application.

    The TWI program has long been recognized for its ability to generate results. After reading this book, you will gain valuable insight into how your organization—whether large or small, national or international—can integrate this timeless tool into your operating structure and your daily culture.


    Setting the Course
    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
    Pilot Project Team
         Steering Team
         Project Manager
         Key Stakeholders
         The Pilot Project Team
              Learning Center Track
              Operations Track
    Pilot Project Description
    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
    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
         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


    Testing the Global LEGO Training Organization and TWI JI
    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
    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


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


    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
    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



    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