1st Edition

Standardized Work with TWI
Eliminating Human Errors in Production and Service Processes





ISBN 9781498737548
Published April 4, 2016 by Productivity Press
191 Pages 35 Color Illustrations

USD $56.95

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Book Description

This book presents what the training within industry (TWI) program is and how its presence affects the understanding of work standardization, focusing on the practical aspects of the implementation of work standardization in the elimination of human errors in manufacturing and service processes.

Table of Contents

Introduction to the Work Standardization Process
What Is Work Standardization?
Human Errors: Are They a Problem at Your Workplace?
Work Standardization as an Effective Approach in the Elimination of Human Errors
Work Standardization: The Foundation of Lean Management and Training within Industry
The Role of the Leader in the Work Standardization Process

Production Process Documentation
Introduction
Descriptive Instructions
Introduction to the Preparation of SWI
41 Rules for SWI Preparation
Application of SWIs for Describing Various Operational Processes (TPM, SMED, Etc.)
Summary

Kaizen-Based Improvement of Production Processes
Kaizen: The Essence of Improvement
Genesis of the Kaizen-Based Improvement Approach
TWI JM Construction and the Importance of 5W1H
Problems in the Joint Application of TWI JM and TWI JI in Production Companies
The Poka Yoke Generator Sheet
Work Method Improvement Using the PYGS as Applied to the Example of Tying the Fire Underwriter’s Knot
System Kaizen and Kaizen Events
Summary

Training Workers
On-the-Job Training Methods
Typical Errors during On-the-Job Trainings in Production Companies
TWI JI Structure
The JBS as the Essential Element of the TWI JI-Based on-the-Job Trainings
TWI JI and the Most Common Mistakes during On-the-Job Trainings
TWI JI-Consistent Training Scenario of Tying the Fire Underwriter’s Knot
Summary of the Training on Tying the Fire Underwriter’s Knot
Estimating the Duration of On-the-Job Training
Calculation of the Estimated Instruction Time for Tying the Fire Underwriter’s Knot
TWI JI Application for Conveying Knowledge, Not Practical Skills: An Introduction to Method Instruction (MI)
Application of MI to Train the Learner on TWI JI
Summary

Work Standardization Process Implementation and Management
Step 1: Planning Work Standardization Implementation and Management (PLAN)
Step 2: Implementation of Work Standardization on Specific Operations of the Selected Pilot Areas (DO)
Step 3: Checking How the Implementation Leaders Apply Work Standardization in the Chosen Pilot Areas (CHECK)
Step 4: Maintaining the Work Standardization Process According to TWI (ACT)
Problems with Work Standardization Implementation

Practical Workshop Dedicated to Work Standardization According to the TWI Program
Preparation for Training
Summary

Afterword

References

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Author(s)

Biography

Bartosz Misiurek, PhD, first gained Lean implementation experience in the automotive and food industries. He then continued developing under the supervision of international experts Marek Piatkowski, a former director of Canadian Toyota, and Richard Abercrombie, a former Boeing manager and a consultant of the TWI Institute. Since 2007, he has been responsible at the Lean Enterprise Institute Poland for the transfer of the TWI program from the United States, and then for its development in Poland. He currently is the chief executive officer (CEO) at Leantrix Company, which among others provides computer systems that aid the implementation of TWI programs.