Making TWI Useful: Ohno’s Secrets

Presented By:

Mark Warren

Session Abstract:

Results of a case study from multiple industries (high volume to low volume – machining, assembly, foundry, textile and office)

Inspired by a 1956 program delivered in Japan that taught problem solving using all three TWI skills and the Management Training Program targeting middle managers. The objective was to create similar results as Ohno did inside Toyota.

The experimental program spends limited time on theory and mostly focuses on application and coaching of the skills. This is done by simplifying the implementation of the TWI skills into the daily routines of supervisors and managers. They made an impact on productivity and quality by using the TWI skills as a problem solving approach.

We will cover how the JI, JR and JM are combined into their problem solving skills, as most problems need more than one TWI skill to properly solve. JR has a much broader application than defined in the 10-hour session, and JM has been simplified to drive regular improvement (most improvements are done in a single day, some take a week).

Will share the set of worksheets and pocket cards that we used to assist leaders to apply the TWI skills in their regular work. Plus an outline of the Follow Up activity required by management.

Learning Objectives:

“In this session you will learn…”

  • The difference between “Learning the Skills” and “Using the Skills
  • That you can teach all three TWI skills sequentially.
  • That JR is far more than just a “people problem” resolving tool, or ‘how to treat people”
  • A practical format on applying JM
  • The critical importance of Follow Up

Presenter Bio:

Mark Warren has 30 years of experience working with a broad range of companies to improve their manufacturing productivity and quality.

Establishing an independent consultancy in 2002, he provides advisory services to management in cooperative projects at various client, supplier and customer facilities in North America, South America, Europe, and Asia.

As a result of his extensive research of the TWI programs in the National Archives and private collections around the world, he has edited and authored several TWI related books.