191 pages | 35 Color Illus.
Standardized Work with TWI: Eliminating Human Errors in Production and Service Processes presents the Training within Industry (TWI) program and describes how it can influence and alter one’s understanding of work standardization. Work standardization is the key to eliminating human errors from manufacturing and service processes. Work standardization is not just the creation of job instructions—it is a comprehensive approach in which employees are formally trained and their skills in the area of work improvement are developed by kaizen sessions. With poor instructions, though, the effectiveness of these two key activities in the work standardization process is practically impossible to achieve.
The book introduces you to 41 rules for standard work instruction (SWI) preparation. Following these rules will ensure that the instructions in your company are ideally suited to train operators and improve work. The author developed these rules based on his professional experience and practice within the TWI program in more than 120 manufacturing and service enterprises, while creating thousands of SWIs. These rules are a clear set of signposts that will help you develop a correct SWI on the first attempt without any unnecessary correction of errors. The quality of SWIs significantly affects how on-the-job training sessions are run, as well as how work analysis with respect to improvement is conducted.
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 to the Preparation of SWI
41 Rules for SWI Preparation
Application of SWIs for Describing Various Operational Processes (TPM, SMED, Etc.)
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
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
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