Training Within Industry: The Foundation of Lean

Donald Dinero

CRC Press, May 27, 2005 - Business & Economics - 352 pages

Winner of a Shingo Prize for Excellence in Manufacturing Research

Training Within Industry, by Donald Dinero, explores a crucial piece of a Lean initiative that has been overlooked throughout U.S. industry. The Training Within Industry (TWI) program — developed by the United States during World War II — has been used by Toyota for decades! This powerful program standardizes training processes and assists front-line supervisors in teaching new operations to workers quickly and effectively.

Dinero completely explores the history and application of the four modules that compose TWI:Job Instruction — in which employees are trained to perform their tasks as quickly as they are capable with minimal waste; Job Methods — in which employees are taught how to improve their processes using existing resources; Job Relations — in which personnel problems are solved in an analytical, non-emotional manner so that employees are focused on a stated objective; and Program Development — in which robust training plans are developed to meet the particular needs of a specific plant.

Readers of Training Within Industry will see that standardized work imparts measurable continuous improvement because it sets a baseline. It establishes a framework for efficiency and innovation.

In addition, the book includes a CD containing the text of original TWI bulletins issued by the U.S. government in the 1940s. Unique and Compelling Features and Benefits:

• Provides a key to successfully implementing Lean Thinking
• Provides basic knowledge without any non-valued added material
• Applies to all positions in all industries
• Time tested - has been used for over sixty years and is still successful

Contents

• Benefits of the TWI Programs: 3
• Developing AllRound Skilled Craftsmen Through Apprenticeship: 4
• TWI is Not Just for Manufacturing: 9
• TWIA Precursor to the Learning Organization: 16
• Initial Startup Challenges: 24
• Expanding the Managerial Organization 6 Strengthening the Managerial Organization 7 How to Prepare Instructors to Give Intensive Job Instruction ...: 28
• Promotional Efforts: 33
• The J Programs: 40
• Why TWI IS A Foundation of Lean Thinking: 47
• Becoming Lean Requires a Culture Change: 53
• The Power of the J Programs: 56
• TWI Requires Useable Techniques: 62
• Simplicity: 68
• Usability: 74
• Summary of Essential TWI Characteristics: 81
• How TWI Developed the Job Relations Program: 109
• Applying Job Relations to a Union Environment and Other Groups: 119
• Launch of the Job Methods ProgramJanuary 1942: 125
• Version VIIFinalized and First Printed Manual: 131
• How TWI Developed Program Development: 137
• Further Adjustments to the PD Program After Release: 143
• Delivering Job Instruction: 153
• Commonality in the TWI Program Manuals: 155
• Job Instruction Session IIHow to Get Ready to Instruct: 170
• Using Job Demonstrations to Deliver JI Training: 179
• Three Special Instruction Problems: 188
• Job Relations Session I: 197
• Job Relations Session II: 208
• Job Relations Session III: 216
• Job Relations Session V: 222
• Delivering Job Methods: 227
• Introducing the JM 4Step Method: 237
• End of Session I and Preparation for Session II: 249
• Using the Job Methods Plan: 257
• Delivering Program Development: 265
• Program DevelopmentSessions IIIX: 280
• Using Program Development: 287
• Creation of a Governing Body: 294
• 315: 315
• 59: 317
• 68: 323

Bibliographic information

• Title: Training Within Industry: The Foundation of Lean
• Author: Donald Dinero
• Edition: illustrated
• Publisher: CRC Press, 2005
• ISBN: 1563273071, 9781563273070
• Length: 352 pages
• Subjects: Business & Economics / Quality Control; Technology & Engineering / Manufacturing