TWI and Kata: The Daily Practice of Kaizen

Presented By:

Patrick Graupp

Session Abstract:

From its roots in WWII war materiel manufacturing, the TWI methodologies were introduced and spread throughout post-war Japan, most famously at Toyota, and were instrumental in the resurgence of Japanese industry beginning as early as the 1950s. It is no surprise then that the basic skills of Job Instruction (JI), Job Relations (JR) and Job Methods Improvement (JM) would form the foundation of good Lean practice. Today, companies striving to implement Lean initiatives throughout the world are more and more turning to TWI to maximize the benefits from Lean with a proven way to focus on the people side of Lean and build a solid foundation through effective front line leadership and coaching.

More recently, TWI practitioners have recognized basic similarities between the practice of TWI and Toyota Kata. This is not a coincidence considering TWI’s influence on Japanese industry when Lean practice was still in the early stages of development. The emphasis on practicing routines in order to master them (make them daily habits) flows through both disciplines. What is more, the TWI skills complement and enhance the advancement of the Improvement Kata and align perfectly with the Coaching Kata.

In this session we will present examples of the Improvement Kata in daily practice in order to show the application of TWI skills on a regular basis that makes continuous improvement continuous. We will review the TWI methods and demonstrate how they lead to definitive progress directed by the Coaching Kata. You will see how the synergy between the two approaches can enhance the practice of both.

Learning Objectives:

In this session you will learn…

  • How JI, JR and JM build effective front line leaders and coaches
  • How TWI integrates with Toyota Kata practice and is the foundation of Kaizen and CI methodologies
  • How the TWI methods provide skills directly applicable to the Improvement Kata
  • How TWI practice enables supervisors to coach team members to navigate toward targets in the Coaching Kata

About the Facilitator:

Patrick Graupp, Senior TWI Master Trainer, TWI Institute

Patrick began his training career at the SANYO Electric Corporate Training Center in Japan after graduating with Highest Honors from Drexel University in 1980. There he learned to deliver TWI from his mentor Kazuhiko Shibuya. Mr. Shibuya was trained by Kenji Ogawa who was trained by the four TWI Inc. trainers sent from the US to help Japan rebuild industry in 1951. Patrick earned an MBA from Boston University while heading Sanyo’s global training effort. He was later promoted to the head of Human Resources for SANYO North America Corp. in San Diego, CA where he settled.

 Patrick helped establish the TWI Institute, which has since trained a rapidly expanding global network of over 1000 certified trainers who are now delivering TWI training in the manufacturing, health care, construction, energy, and service industries in the US and around the globe. He has authored numerous books on TWI including The TWI Workbook: Essential Skills for Supervisors, Implementing TWI: Creating and Managing a Skills-Based Culture, Getting to Standard Work in Health Care: Using TWI to Create a Foundation for Quality Care and Building a Global Learning Organization: Using TWI to Succeed with Strategic Workforce Expansion in the LEGO Group. The TWI Workbook and Building a Global Learning Organization are Shingo Research and Professional Publication Prize Recipients.