Training Within Industry - TWI

TWI - Training Within Industry; What interests me most is creating and maintaining a skill-based culture
What interests me most is creating and maintaining a skill-based culture

Imagine a world, where...

  • Changes go faster as a culture has been developed where honest and solid trust has been created between the employees and the leaders. Good results, are created through good relationships which foster motivation and engagement. 
  • There is created a safety culture that prevents accidents from happening.
  • Your people are maintaining their knowledge and skills  through a effective learningsystem, so all work is carried out correctly, safely and conscientiously everyday.
  • Your processes are continuously improved by making the most of current materials, equipment, tools and resources - every day.

Through the TWI J Programs you can create and maintain this picture above, as all these topics are skills that can be developed through the TWI J Programs. At BTP we believe that leaders create leaders - so therefor, you need to lead and design your system, that will create and maintain these crucial skills and desired culture. In this process we can advise, coach and train you in doing this, step by step in the whole process. 

Below you can find more information about the individual TWI J programs, how to get started, our TWI DNA, the TWI History and the link between TWI and Lean.

 

TWI Job Relations

TWI Job Relations

TWI Job Relations: Your way to increased well-being among your workers as well as effective conflict management.

TWI Job Instruction

TWI Job Instruktion

The way to efficiency is to train your workers to do their job correctly, safely and conscientiously.

TWI Job Methods

TWI Job Methods

TWI Job Methods creates a foundation in your work with continuous improvements, which Toyota nowadays calls "Kaizen".

TWI Job Safety

The way to create and maintain a healthy and safe work environment. This strong TWI program has been developed in collaboration between TWI trainers from the United States and from the Japanese industry, where - so far - the best example of this is Toyota.

TWI Problem Solving

TWI Problem Solving (PS) is a way to teach your supervisors to solve problems - quickly and efficiently. This is done using the three TWI methods (JI, JR & JM) in a systematic manner.

Below you can find some Q&A about TWI:

At BTP we are official Global Partner with the TWI Institute in the United States. We are trained and certified to offer and implement their TWI and Toyota Kata programs. We have the rights to do this in Scandinavia and Switzerland. Our global network of other Global Partners means that we can offer TWI globally.

below statment is from Scott Curtis, Executive Director, TWI Institute, USA:

"The Institute in the last couple of years has seen a fairly significant amount of growth, both in North America and other parts of the world, Europe and South East Asia. So, a good portion of our business was in other regions outside North America. We felt that the best thing to do was to establish partners in locations in those other areas of the world. Really give that area there and its clients the best possible service. And so we were looking to partner with the best and the brightest, and that is where the idea came in of partnering up with companies and people such as John Vellema and Business Through People (TWI Institute Scandinavia and Switzerland)." 

All TWI programs are standardized programs, both in terms of how the supervisors use the methods in daily life and how we as TWI trainers teach during the 10-hour courses with TWI. In short:

  • Each program has a corresponding 4-step method.
  • Each method and training is written in an everyday language.
  • The courses are scheduled as 5x2 hours, divided into 2 hours every day for one week. It is recommended that the participant receives additional coaching so that you really learn the method before you start using it with your workers.
  • The learners are taught in small groups of 6 to 10 people.
  • Each participant practices the method by performing a demonstration during the 10-hour course. An example fromthe TWI Job Instruction course could be that the participants bring a job from their everyday work and try to train a colleague in that job.

All our TWI trainers follow the recognized TWI manuals that have been tested thousands of times globally and adjusted for over 70 years. This is to ensure the best training for your supervisors. All our TWI trainers are certified to teach you the TWI programs according to the requirements established by the TWI Institute in the United States.

 

Our DNA with TWI
  • 1951 - Kenji Ogawa is one of the original and first TWI Master Trainers from Japan to be trained and certified by American trainers.
  • 1960 - Mr. Ogawa educates Kazuhiko Shibuya at Sanyo Electric Corporation.
  • 1980 - Mr. Shibuya trains Patrick Graupp in TWI at Sanyo.
  • 2002 - Patrick Graupp leaves Sanyo to collaborate with the TWI Institute (USA) to revive TWI in the United States.
  • 2010 - Patrick Graupp trains John Vellema in TWI at the LEGO Group.
  • 2012 - John Vellema leaves the LEGO Group to create Business Through People (BTP).
  • 2012 - Business Through People officially becomes TWI Institute Denmark.
  • 2014 - Business Through People grows and officially becomes TWI Institute Scandinavia and Switzerland.
  • 2014 - Joakim Bjurström joins Business Through People and becomes a certified TWI JI Trainer.
  • 2015 - John Vellema completes his TWI Institute train-the-trainer education in TWI Job Instruction, thereby becoming TWI Master Trainer (JI).
  • 2017 - John Vellema completes his TWI Institute train-the-trainer education in TWI Job Relations, thereby becoming TWI Master Trainer (JR).
  • 2017 - Joakim Bjurström becomes KATA Master Trainer for TWI Institute and Business Through People starts offering KATA programs.
  • 2019 - Kalervo Laaksoharju joins Business Through People and becomes a certified TWI JR Trainer.
  • 2020 - Kalervo Laaksoharju becomes a certified TWI JI  Trainer.
  • 2020 - Torben Kjær-Christensen joins Business Through People and becomes a certified TWI JI Trainer.
A proven method and global program

There are over 1000 trained and certified workers delivering TWI 10-hour courses in companies worldwide - with good results. This proves that the TWI Institute certification programs work and that it is a globally tested program.

All our TWI trainers have been approved and certified by the TWI Institute in deliver the TWI programs.

Yes, BTP is also part of the global TWI Network. 

Below you can see how we can provide you with a complete TWI package through this network. A network that will provide value for your organization across borders. We can help you if you already have cross country locations or if you are planning to expand to a new country. Contact us and we will take care of the collaboration. 

America

TWI Institute USA, Headquarters
http://twi-institute.org

Australia

TWI Institute Australia 
http://www.twi-instituteaust.com

Czech Republic

TWI Institute Czech Republic 
http://www.dmc-cz.com

Scandinavia

TWI Institute Scandinavia
http://twi-institut-skandinavien.dk/

Spain and Portugal

TWI Institute Spain 
http://www.instituto-twi.com/

Italy

TWI Institute Italy
The site is under development

England

TWI Institute UK
The site is under development

France

TWI Institute Frankring
The site is under development

Netherlands

TWI Instituut Nederland BV 
http://www.twi-instituut.com

Germany

TWI Institut Deutschland GmbH 
http://www.twi-institut.com

Switzerland

TWI Institute Switzerland 
http://www.twi-institute-switzerland.com/

What is required to become a teacher on a TWI 10-hour course?

For each TWI 10-hour course (TWI Job Relations, TWI Job Instruction, TWI Job Methods, TWI Job Safety and TWI Problem Solving), there is a subsequent TWI 40-hour "train-the-trainer" training that provides access to teaching TWI 10-hour courses. The TWI Institute's learning method is "learning-by-doing" with associated coaching.

Upon completion of the course you will be confident in and have the skills to complete the 10-hour course.

All 40-hour courses are conducted by a Certified TWI Master Trainer. The teaching itself is standardized, but flexible enough to create a positive and supportive learning environment for all participants. The group size is between 4 and 6 participants and therefore allows for 1-to-1 sparring with the Master Trainer.

The 40-hour course can be carried out at your workplace or on an open course. The open courses will be conducted primarily in Denmark and the USA. Contact us for more information on this.

Why should I become a Certified TWI Institute Trainer?

You will be trained by experienced and committed Master Trainers who have proven, through documented successful cases, the usefulness of the method in different industries. All the TWI Institute's certified instructors become part of a community where you can look for and exchange experiences.

What are the requirements for participating in a TWI 40-hour "train-the-trainer" course?

The "train-the-trainer" programs require that you have satisfactorily completed one of the TWI 10-hour programs and then used the learned method with good and stable documented results for at least 4 months.

If you would like to know more about how to become a TWI Institute Certified Trainer, please feel free to contact us here.

World Crisis Creates a Need

In order to understand Training Within Industry (TWI) you need to know the premise for the development of the program itself. TWI was developed in the 1940’s as a counter-reaction to the sudden gap in the workforce if the US was drawn into the war in Europe. In order to ramp-up production to supply the Allied army it was a necessity to “enlist” millions of people that had never worked in a factory before to the workforce, with one-half of them women that were used to the role of housewife. Therefore it was of great urgency that a training program for the inexperienced worker be developed.

A national network of professionals was “drafted” from industry and academia to develop techniques to quickly ramp up the production of war materials by focusing on training supervisors who would then train the people that reported to them:

Connect the sentence below to make this one paragraph “To help industry to help itself to get out more materials than have ever been thought possible, and at constantly accelerating speed” defined the mission of the program.

Based on a wide skills-gab analysis the national network constructed the dynamic TWI program that combines hands-on learning and practice, teaching essential skills for supervisors, team leaders, and anyone who directs the work of others.

Before the ink on the programs’ blueprint had time to dry the program, with support from the US Government was rolled out on a national scale. The impact of the TWI Program within the US was very clear and it quickly showed itself extremely valuable for the industry. With its almost domino-like effect, spread faster than one could have ever hoped for.

Probably one of the first and best cases, is that of the B-17 airplane, where the workers reduced the hours per airplane with 60% - not only did the TWI program effectively help train the inexperienced workforce it also trained them in how to improve the processes.

It was not only the speed of production that benefitted from the program, looking at the financial benefits, the Initial cost was $242,000 per plane in 1940 and was reduced to a final cost of $139,254 in March 1944, a reduction of 42.46% in only 32 months.

How?

One of the reasons for the success of TWI is due to its simplicity. Based on straight to the point principles and no-nonsense attitude it was directed toward the worker, not management. Jobs Instruction (JI) are broken into easy and manageable steps instructed in “shop talk” language the workers understand. This was done in order to comprehend both the visual illustration of the job and at the same time follow the verbal instructions. The combination of the learn-by-doing and clear set of steps that are supported by key points was exactly what the US. Workforce needed to enroll a completely fresh batch of recruits. But how were they able to implement and succeed with this in such a short time? One of the absolute most brilliant parts of the program is the “multiplier effect” that spreads the training throughout an organization. By having a train-the-trainer approach you are able to quickly multiply the number of trainers and hence the number of trained workers This sentence will confuse the reader. Now you might think “but will all of this training when will they actually be producing?”. This is one of the key points of the TWI program as the training will be taking place realistic surroundings and the worker will never be away from work more than necessary. This way the production line will not lose an essential asset and at the same time the trained worker will be able to see and reflect on the training process they are undergoing. This interaction of practice and work is the optimal way of learning anything; from the simplest procedure to most complicated task.

Why was TWI abandoned?

After the war the composition of the American workforce naturally changed severely as the millions of men and woment that served in the military returned to their normal jobs. This meant that all of the TWI trained staff was replaced; effectively putting a stop to the use of TWI to train new workers. Furthermore the program was viewed as a war program not suited for the long term progression and inadaptable for a non-war industry. The fact that TWI had placed a great amount of focus on the work environment and on how people were treated on grass-root level did not help the program in cold war America, as this way of thinking resembled socialism a little too much. US infrastructure was one of the few not damaged by the war enabling manufacturers to quickly shift to the mass production of consumer goodsTWI rejser til Japan

TWI Travels to Japan

Abandoned by American industry after WWII TWI was introduced to Japan by the US Occupational Government along with the quality methods of Deming and Juran to rebuild the shattered Japanese industrial base to prevent the spread of communism At this point Japanese industry was running at a less than 10% of its 1935-1937 level and was therefore eager to learn from the very industrial base that had defeated them.

They soon saw the qualities and benefits of the TWI program that quickly became a staple of Japanese industrial training. It showed exactly to be just as successful as within the US Workforce as it spread throughout the industry. “When the TWI, Inc. specialists departed Japan, they left behind them 35 certified Institute Conductors. The beginning of a large multiplier effect, which extended to over one million Japanese managers and supervisors by 1966, and to many millions more by 1992.” One of the companies that took in TWI was Toyota. In 1951 Toyota used TWI to train their people in the evolving Toyota Production System. TWI has remained a cornerstone of their team leader training and standard work ever since.

Training within Healthcare, in a Historical perspective:

It was not only the American workforce who benefitted from the program during the war years. The healthcare sector quickly realized how effective the program was and started implementing it.

Training Within Hospitals, 
Ellen L. Aird, R.N., The American Journal of Nursing, 1943 

We Cannot Afford To Hurry
Sister Mary Brich, R.N., The American Journal of Nursing, March 1944 

TWI Methods of Teaching Auxiliary Nursing Personnel
Olive White, The American Journal of Nursing, June 1944

Mange kalder TWI for ”the missing link in Lean” og ”the human side of Lean”

Hvorfor gør man det? hvad er det som TWI, støtter Lean med? og hvorfor anses det som fundamentet i Lean? 

En Shingo analyse fortæller os, at 85% af alle Lean projekter mislykkes. Så hvorfor, fejler 85% af alle Lean Projekter?

  • Når Standardiseret arbejde ikke er Standardiseret arbejde?
  • Når det mere er ord i dokumenter end egentlig adfærd hos vores lederne &
    medarbejderne!
  • Hvordan omsætter vi vores standarderne til adfærd hos vores ledere og medarbejder? 

 Hvad vil dine supervisors svare til disse spørgsmål?

  • Er du blevet trænet i en effektiv og systematisk metode, der vil hjælpe dig til at forbygge og løse medarbejder konflikter?
  • Har din virksomhed en effektiv og systematisk metode, til at hurtigt at træne medarbejder til at løse en opgave korrekt, sikkert og samvittighedsfuldt?
  • Er du blevet trænet i en effektiv og systematisk metode i at hjælpe med at forbedre medarbejdernes jobs?

Måske, kan du sige ja til nogle af disse spørgsmål, men har I også opbygge organisationen og ledelsesystemet - så sikre en systematisk drift af dette, på en anderkende og motiverne måde? 

Vi ser, at de fleste af dem mislykkes, fordi de mangler TWI supervisor struktur og TWI programmer. Jeffrey Liker skriver det godt i Toyota Way bogen "De fleste virksomheder har fokuseret for meget på værktøjerne... uden at forstå Lean som et helt system, der skal gennemsyre organisations kulturen", samt det kom også meget tydeligt frem, da man spurte Isao Kato, faderen af Standardiseret Arbejde og Kaizen træningskuserne hos Toyota - omkring TWI invirkning på TPS (Toyota Produktions System) svarede han:

“The JI thinking is really critical and somewhat under-appreciated in TPS formulation. The capability to breakdown a job is fundamental in terms of helping create a standard for teaching others. It is much easier and smaller step than to create the three elements of Standardized Work (takt time, work sequence, and standard amounts of work-in-process) after JI is in place. Plus when you change takt time and move work around JI is the perfect vehicle to train people. For this reason I believe and I think that Mr. Ohno would agree that JI had by far the biggest impact on TPS formulation.”

De fleste lean projekter, fokuser for meget på værktøjerne og ikke på organisationen og systemet - det er her at TWI, er med til at skabe det vigtige fundament der er tested flere 1000 gange globalt. Man tro at man opnår en kultur forandring ved at implementer værktøjerne, men det gør man ikke - det er som Col. Chet Rachards, fra USAF skrev "Kulturen følger Systemet"

De tre TWI programmer arbejder sammen, som en trebenet skammel –

Hvis du fjerner et af benene vælter hele skamlen.

TWI Understøtter Lean med:

  • TWI JI  – Standardiseret arbejde
  • TWI JR – Respekt for mennesker
  • TWI JM – Løbende forbedringer

Herunder ses hvordan TWI og Lean støtter hinanden i opbygning af en løbende forbedringskultur. Springer man et trin over, vil fundamentet ikke være stabilt og derved vil det opbygget system ikke være blivende.

Kilde: Bogen - Implementing TWI side 129Hvad er linket imellem TWI og Lean?

En af styrkerne som TWI også har påvirket Toyota med, er supervisor strukturen. Hos Toyota har en Teamleder normalt 5 medarbejder, denne struktur er med til at sikre at disse nøgle medarbejder kan træne, motivere og prosess forbedre - samtidig med at de også fastholder deres erfaring med det faglige arbejde. De er en slags spillede træner. I TWI siger vi at man kan lede op til 10 personer. alt for mange organisationer der arbejder med Lean idag, tænker ikke meget over hvordan deres organisationsdesign skal se ud hvis de gerne vil lykkes med lean - her giver TWI også mange af de svar de mangler.

Det er her, at vi mange gange glemmer at fokusere vores indsats - hvem vælger disse vigtige nøgle personer, hvem forventnings afstemmer deres rolle, hvem uddanner disse personer og hvem følger op på om disse personer er effektive i deres arbejde med medarbejderne? Dette er det suport system der sikre en drift at ledelse systemet. 

What is required to become a teacher on a TWI 10-hour course?

For each TWI 10-hour course (TWI Job Relations, TWI Job Instruction, TWI Job Methods, TWI Job Safety and TWI Problem Solving), there is a subsequent TWI 40-hour "train-the-trainer" training that provides access to teaching TWI 10-hour courses. The TWI Institute's learning method is "learning-by-doing" with associated coaching.

Upon completion of the course you will be confident in and have the skills to complete the 10-hour course.

All 40-hour courses are conducted by a Certified TWI Master Trainer. The teaching itself is standardized, but flexible enough to create a positive and supportive learning environment for all participants. The group size is between 4 and 6 participants and therefore allows for 1-to-1 sparring with the Master Trainer.

The 40-hour course can be carried out at your workplace or on an open course. The open courses will be conducted primarily in Denmark and the USA. Contact us for more information on this.

Why should I become a Certified TWI Institute Trainer?

You will be trained by experienced and committed Master Trainers who have proven, through documented successful cases, the usefulness of the method in different industries. All the TWI Institute's certified instructors become part of a community where you can look for and exchange experiences.

What is required to become a partner with TWI Institute Scandinavia?

To become a partner with TWI Institute Scandinavia, you must have completed the following certification process satisfactorily:

  • Finding a host company (that allows you to be part of their TWI implementation and buy one of their 10 places on the TWI 10-hour courses).
  • Satisfactorily having completed a TWI 10-hour course (at host company). Preferably both TWI JI and TWI JR.
  • Having used the learned method with good and stable documented results for at least 4 months along with the host company.
  • Having completed the TWI 40-hour course, preferably both TWI JI and JR.

There are 2 types of partners in TWI Institute Scandinavia:

  • Get permission to use TWI Institute Scandinavia products through your own company and use the TWI Institute Scandinavia collaboration logo on the website as well as sales materials and be connected to/from the TWI Scandinavia website.
  • After repeated good results and a large number of completed TWI 10-hour courses, as an internal or external TWI trainer, you can apply to become one of TWI Institute Scandinavia's own TWI trainers. Here you will be included on the TWI Institute Scandinavia website with a trainer profile and related marketing opportunities.

If you would like to know more about how to become a partner with TWI Institute Scandinavia and thereby a TWI Institute Certified Trainer, please feel free to contact us here.