1st Edition

TWI Case Studies Standard Work, Continuous Improvement, and Teamwork

By Donald A. Dinero Copyright 2011
    136 Pages 1 B/W Illustrations
    by Productivity Press

    136 Pages
    by Productivity Press

    TWI Case Studies: Standard Work, Continuous Improvement, and Teamwork provides the insight of leading experts to assist in the execution of Training Within Industry (TWI)—the game-changing business tool. Presented as a series of case studies from a range of corporations with a variety of products and needs, it illustrates the rebirth of TWI programs in the United States.

    Demonstrating how TWI can benefit any and all organizations regardless of industry, the book details the specific activities decision-makers need to accomplish to successfully incorporate TWI into the business culture—including the Ten Points for Implementing and Sustaining the TWI "J" Programs. The case studies describe the use of TWI Programs at some of the world's leading companies, including:

    • IBM
    • Herman Miller
    • Ben & Jerry's Homemade Ice Cream
    • Green Mountain Coffee Roasters
    • US Synthetic

    Born in the 1940s, and used to support the US military during World War II, TWI Programs later became the unrecognized yet powerful tools of the Toyota Production System. Imparting the fundamental skills that are useful across any field, the TWI programs described in this book are so fundamentally sound that using them to any degree will improve performance. Strict adherence will all but guarantee efficient work flow, higher employee morale, and an improved sense of cohesiveness among your employees.

    Use and Misuse
    Reasons for Lack of Success
    Lack of Commitment
    Unforeseen Circumstances
    Underestimating the Required Effort
    Insufficient Experience
    Principal Reason for Lack of Success
    The Path to Success

    A Variety of Improvements
    Great Gains—Focused Application
    Garment Manufacturing
    Aircraft Manufacturing
    JIT: "The Acid Test"—Mabati Rolling Mills, Mombasa, Kenya
    Standard Training and Standard Work Support Growth—The U.S.
    Synthetic Company
    The Power of Standard Work and Its Importance in a Regulated
    Company—The Autumn Harp Company
    What Was Done Right
    What Could Have Been Done Differently
    Improvements After 120 Years—The Ludowici Roof Tile Company
    Implementation and Use
    The Use of Job Relations Training—The Rhino Foods Company
    An Urgent Need for Job Relations Training

    Green Mountain Coffee Roasters—Continuous Growth
    Implementation and Use
    Keurig Lines
    WIP Areas
    Done Well and Opportunities for Improvement

    IBM—A Revival
    The Reintroduction of TWI at IBM
    Quantifying Benefits
    Sustaining TWI
    Problem-Solving Structure
    JIT in the Supply Chain

    Ben & Jerry’s Homemade Ice Cream—A Tale of Two Plants
    The Beginning
    Becoming Trainers
    Starting JIT at St. Albans
    Integrating JIT with Existing Activities
    What Can Be Learned
    Publish Results
    Creating JBSs
    A TWI Champion
    Training Institutes
    Other Results

    Herman Miller—How Lean Are You?
    Herman Miller’s Journey into Lean
    The Need for TWI Job Instruction
    An Approach to Develop Job Instruction
    Results and Learning

    Case Study Sources


    Donald A. Dinero, PE, CPIM, has more than forty years of experience designing and implementing manufacturing methods and processes, and is the principal of The TWI Learning Partnership. He has addressed problems in all aspects of operations including, but not limited to, change management, personnel, labor unions, production systems, and production control.

    His BS in mechanical engineering is from the University of Rochester and his MBA and MS (Career and Human Resource Development) are from the Rochester Institute of Technology. Don deliberately sought degrees in these areas so that he would have a balanced academic background in technology, business, and organization development. He received his Professional Engineering license (NYS) in 1983 and his Certification in Production and Inventory Control from APICS in 1986.

    After over thirty years in positions of manufacturing and engineering management and as a direct contributor, Don entered the Lean consulting field by joining existing consulting firms. In 2002, he learned about TWI (Training Within Industry) and its reemergence in the U.S. After becoming developed as a TWI trainer in the three "J" courses, he began to study all the materials he could find on the subject. His studies and talks on TWI led to his writing the book Training Within Industry: The Foundation of Lean, published by Productivity Press, 2005. This book won a Shingo Prize for Research in 2006.

    As he continued implementing Lean concepts, he began to realize that the Lean movement was hindered by its omission of TWI training. TWI offers fundamental skills training that helps to stabilize an organization, preparing it to seriously begin its Lean journey. In addition, it provides a foundation so that Lean principles are sustained. In order to assist in stabilizing an organization and, thus, assist in the acceptance of Lean, Don is concentrating his efforts on spreading the word of TWI. His consulting practice focuses solely on the TWI Programs. To that end, he delivers training in all three of the "J" programs and in Program Development. In keeping with the "multiplier effect" cited by the Training Within Industry Service, Don also offers Train the Trainer sessions for all four programs. This allows an organization’s employees to independently deliver the training.

    Don is not only a teacher of the TWI Programs, he is also a student of them and is continually learning about them through experiences with clients and reading. As a result, he continues to write papers about what he has learned, which appear on his website and in other publications. He also presents at the annual TWI Summit and at various other conferences around the world. More importantly, however, is that by having a deep understanding of TWI combined with forty years of industrial experience, he is well suited to successfully implementing these Programs into any organization.

    Knowing that the TWI Programs consist of fundamental pedagogical principles, Don believes that these programs should be delivered in middle and high schools for the benefit of both teachers and students. Getting closer to this goal, Don has recently began working with the Be Like Coach organization (BeLikeCoach.com), which is a non-profit organization dedicated to bringing good coaching techniques to America’s coaches in order to benefit youth sports at all levels (recreation, school, club/elite).

    As a student of TWI, Don continues to have a desire to learn and improve with respect to the TWI Programs. He welcomes all input and feedback and can be contacted at [email protected].