1.3 Supervisory Skills

Although Lean is increasingly recognized worldwide as the most productive approach to manufacturing, most companies do not realize that Lean is actually a blend of both old and new concepts. Henry Ford recognized in 1926 that he could keep product prices low by shortening the production cycle and implementing standardization, which allowed him to build his manufacturing empire on these concepts.

Established by the Roosevelt administration after the fall of France in 1940, the Training Within Industry (TWI) program was tasked with rapidly boosting industrial production, productivity, and quality to sustain the war effort. This program was later adopted by Toyota, forming a cornerstone of eliminating waste, standardizing work, and creating a culture of continuous improvement.

The TWI Program offers the following five courses:

• TWI – Job Methods Improvement
• TWI – Job Instruction for Standardized Work
• TWI – Job Relations
• TWI – Job Safety
• TWI – Problem Solving (Qualitative)

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TWI – Job Methods Improvement

Overview:

The TWI – Job Methods Training program aims to enhance productivity by enabling the production of greater quantities of quality products in less time. This course focuses on optimizing the use of available people, machines, and materials. Supervisors will learn to break down jobs into their constituent operations, fostering a mindset of inquiry to question existing processes. By examining details closely, participants will develop innovative methods that eliminate, combine, and rearrange tasks, leading to improved efficiency and effectiveness in the workplace.

Key Benefits:

• Increase production output while maintaining quality
  
• Optimize resource utilization, including workforce and equipment
  
• Foster a culture of continuous improvement and innovation

Course Objectives:

• Learn to break down jobs into constituent operations for analysis
  
• Develop skills to question and improve existing processes
  
• Create new methods that enhance efficiency and productivity

Duration:
8 hours

Certification Notes:
Participants will receive a course completion certificate upon successful completion.

Enrollment:
Click the "Send a Request" button below to learn more about the courses and schedule a consultation with our expert.

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TWI – Job Instruction Training

Overview:

In today's fast-paced and dynamic work environment, the demand for a flexible and well-trained workforce is greater than ever. This course equips attendees with essential skills to effectively break down jobs and deliver structured instruction for individual tasks. By utilizing standardized best practices, participants will foster process stability and enhance operational efficiency. The Job Instruction method emphasizes preparing operators for learning, delivering effective demonstrations, observing task performance, and providing ongoing coaching. This structured approach empowers participants to create a safe, efficient, and motivated workforce.

Key Benefits:

• Reduced training time
  
• Minimized scrap and rework
  
• Fewer accidents and safety incidents
  
• Increased job satisfaction and confidence

Course Objectives:

• Understand and demonstrate the 4-step method of instruction
  
• Learn how to create a job breakdown
  
• Develop skills to create a training matrix

Duration:
5 consecutive days – 2 hours per day

Certification Notes:
Participants will receive a course completion certificate upon successful completion.

Enrollment:
Click the "Send a Request" button below to learn more about the courses and schedule a consultation with our expert.

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TWI – Job Relations

Overview:

The TWI – Job Relations training focuses on understanding human behavior and building strong workplace relationships. This course emphasizes the importance of treating individuals with respect and fostering positive interactions among team members. Supervisors will learn foundational principles for developing and maintaining good relationships to prevent conflicts and enhance collaboration. Key principles include providing constructive feedback, recognizing employee contributions, informing team members about changes that may impact them, leveraging each individual's strengths, and cultivating loyalty and cooperation. Additionally, the training equips supervisors with problem-solving skills, guiding them on how to gather facts, evaluate situations, make informed decisions, take appropriate actions, and assess outcomes. Participants will also learn to distinguish between two fundamental types of problems: those related to products and processes, and those concerning interpersonal relationships.

Key Benefits:

• Enhance interpersonal skills to build effective workplace relationships
  
• Learn proactive strategies to prevent conflicts and misunderstandings
  
• Develop problem-solving techniques to address issues effectively

Course Objectives:

• Understand the importance of treating employees as individuals
  
• Master techniques for providing feedback and recognizing contributions
  
• Acquire skills to resolve conflicts and make informed decisions

Duration:
8 hours

Certification Notes:
Participants will receive a course completion certificate upon successful completion.

Enrollment:
Click the "Send a Request" button below to learn more about the courses and schedule a consultation with our expert.

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TWI – Job Safety

Overview:

TWI – Job Safety is an essential program designed to complement the traditional TWI instructional model by emphasizing environmental health and safety practices. This course provides supervisors with a structured framework to actively engage employees in identifying potential hazards and implementing strategies to eliminate them. Drawing on training in OSHA and EPA regulations, JS equips supervisors with the knowledge necessary to foster a safer workplace. Developed in Japan, this program may not have been part of the original TWI curriculum, but it has become critical in today’s industrial environment. Participants will learn to analyze the chain of events that lead to accidents and hazardous situations, identifying and addressing root causes to effectively "break the chain." Furthermore, the program highlights the crucial role of the supervisor-employee relationship in promoting a safe and environmentally responsible workplace.

Key Benefits:

• Develop a proactive approach to identifying and mitigating workplace hazards
  
• Understand OSHA and EPA regulations to ensure compliance and safety
  
• Strengthen supervisor-employee relationships to enhance safety culture

Course Objectives:

• Learn methods for analyzing accidents and hazardous situations
  
• Identify and remediate root causes of safety incidents
  
• Foster employee engagement in safety initiatives

Duration:
8 hours

Certification Notes:
Participants will receive a course completion certificate upon successful completion.

Enrollment:
Click the "Send a Request" button below to learn more about the courses and schedule a consultation with our expert.

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TWI – Problem Solving (Qualitative)

Overview:

The TWI Problem Solving (TWI PS) course employs the three TWI methodologies for the purpose of solving problems. Companies that already utilize one or more of the TWI skills can leverage these supervisory abilities and gain even more value from them. This course gives renewed meaning to the TWI methods with a focused emphasis on problem solving. Moreover, TWI PS offers a valuable opportunity to refresh, review, and reinvigorate the application of these powerful skills within the workplace.

Most companies aspire for their front-line supervisors to be self-sufficient and capable of solving the problems they encounter, rather than waiting for someone else to address them. The TWI Problem Solving program serves to consolidate and integrate the proven TWI methodologies of Job Instruction (JI), Job Relations (JR), and Job Methods (JM) under one cohesive plan for this purpose. By reflecting on the progress of Japanese industry since the introduction of these TWI programs, we can appreciate the significant contribution that Mellon and his group made, which has led to the establishment of today’s Gold Standard of manufacturing excellence – the Toyota Production System.

Key Benefits:

• Renew the application of TWI methodologies in problem-solving contexts
• Empower front-line supervisors to take initiative in resolving issues
• Strengthen the overall problem-solving capabilities within the organization
• Learn from the success of the Toyota Production System as a model for excellence

Course Objectives:

• Understand the TWI methodologies of JI, JR, and JM
• Apply these methodologies specifically to problem-solving scenarios
• Foster a culture of self-sufficiency among supervisors
• Refresh and enhance the use of TWI skills in the workplace

Duration:
40 hours

Certification:
Upon successful completion of the course, participants will receive a course completion certificate.

Enrollment:
Click the "Send a Request" button below to learn more about the course and schedule a consultation with our experts.

Send a Request