Watch the full presentation: http://www.dozuki.com/resources/register-for-training-within-industry-101 Looking for a standard framework to scale and train your teams? Curious about how LEGO applies TWI to its global workforce? Want to know what manufacturing and healthcare industries have in common? Our conversation with Patrick Graupp of the TWI Institute covered it all. Highlights include an example of how to create a job breakdown and how proper job training helps reduce operating costs across industries. This presentation includes: - How to break a job down for instruction - How TWI helps train remote employees - What is a 'key point' - How to set up an organizational training structure - How to continue to improve instructions with employee feedback - ... and more

2. TRAINING WITHIN INDUSTRY
GUEST EXPERT: PATRICK GRAUPP

3. TRAINING WITHIN INDUSTRY
GUEST EXPERT: PATRICK GRAUPP

4. 1. Origins of TWI
2. TWI Today
3. Training Programs
4. Practical Examples of TWI in Action
5. Review & Resources for More Learning
TODAY’S ROADMAP
T H E W O R K S H O P S E R I E S

5. What’s your interest in TWI?
‣ Generally curious
‣ Active Practicioner
QUICK POLL!
T H E W O R K S H O P S E R I E S
‣ Did it before, want to review
‣ Going to start using TWI

6. TWI HELPED WIN WWII
•
With a gun to their heads (literally),
the TWI founders had to find solid
principles of human nature that:
•
Work every time
•
Inspire dedication
•
Create performance results
•
Build leadership
•
Strengthen teamwork
T H E W O R K S H O P S E R I E S

7. IMPACT OF TWI ON THE WAR EFFORT
Of the 600 client companies monitored by the
TWI Service throughout the war:
•
86% - increased production by at least 25%
•
100% - reduced training time by 25% or more
•
88% - reduced labor-hours by over 25%
•
55% - reduced scrap by at least 25%
•
100% - reduced grievances by more than 25%
T H E W O R K S H O P S E R I E S

8. TWI GOES TO JAPAN
Toyota embraced TWI in 1951 to train their people in
the evolving Toyota Production System and remains a
cornerstone of their team leader training and standard
work today
T H E W O R K S H O P S E R I E S
Taiichi Ohno
Founder of the Toyota Production System (TPS)

9. “If people want to succeed
with lean or TPS they have to
emphasize people
development and making
leaders capable of delivering
improvements. TWI is a great
starting point even today and
a hidden strength of Toyota’s
production system.”
BENCHMARKING WITH TOYOTA
T H E W O R K S H O P S E R I E S
www.ArtofLean.com

10. TODAY REACHING THE GLOBAL MARKET
T H E W O R K S H O P S E R I E S

11. BASIC NEEDS OF GOOD SUPERVISORS
T H E W O R K S H O P S E R I E S
KNOWLEDGE
SKILL
Work
Responsibilities
Instructing
Improving
Methods
Leading
Safety

12. 3 TRAINING PROGRAMS FOR 3 SKILLS
T H E W O R K S H O P S E R I E S
Skill in instructing
Skill in improving
methods
Skill in Leading
Job Instruction
Training
Job Methods Training
Job Relations Training

13. SYNERGY BETWEEN THE 3 SKILLS
The three TWI programs work together like a three-
legged stool — take one leg away and the stool falls
down.
JR – Motivated people
JI – Standard work
JM – Continuous Improvement
T H E W O R K S H O P S E R I E S

14. JOB INSTRUCTION TRAINING (JI)
How to teach people to quickly learn to do a job
correctly, safely, and conscientiously. JR – Motivated
people
T H E W O R K S H O P S E R I E S

15. Step 3 - Try-out Performance
Continue until you know they know
Step 4 - Follow-up
Encourage questions
JI 4-STEP METHOD
Step 1 - Prepare the Worker
Get the person interested in learning
the job
Step 2 - Present the Operation
Don’t give them more information than
they can handle at one time
T H E W O R K S H O P S E R I E S
”If the worker hasn’t learned the instructor hasn’t taught.”

16. STEP 2 – PRESENT THE OPERATION
T H E W O R K S H O P S E R I E S
• Tell, show and illustrate one Important Step at a time
•
Do it again stressing Key Points
•
Do it again stating reasons for Key Points
•
Instruct clearly, completely and patiently but don’t give
them more information than they can master at one
time.

17. T H E W O R K S H O P S E R I E S
No. __________
JOB INSTRUCTION BREAKDOWN SHEET
Operation: ____________________________________________________
Parts: ________________________________________________________
REASONSKEY POINTSIMPORTANT STEPS
Reasons for key points
Anything that might—
1. Make or break the job
2. Injure the worker
3. Make the work easier to do, i.e.
“knack”, “trick”, special timing, bit of
special information
A logical segment of the operation when
something happens to advance the work
People learn better when they know
why they do it that way.
The 5 or 10% of a job that represent the
.hard or tricky parts
.Not a micro-motion study of the job
WHAT HOW WHY

18. WHAT IS AN IMPORTANT STEP?
When putting a new blade in a hacksaw:
‘Take hold of the wing nut’ is not a step worth noting during
instruction. The operator will get this without being told.
‘Turn down the wing nut’ is a step, but it is not an Important
Step. It does not advance the work.
‘Adjust the tension on the blade’ is an Important Step. It is
the most important thing that happens here in order to
advance the work. It is unnecessary to go into greater detail.
T H E W O R K S H O P S E R I E S

19. KEY POINTS ARE “KEY”
Key points don’t mean every conceivable thing that
is to be watched, or which might go wrong. There
is no need to go that far into detail
Knowing what the Key Points are and how to pick
them out quickly and easily is perhaps the most
important thing in Job Instruction.
T H E W O R K S H O P S E R I E S

20. When putting a micrometer on a piece of stock, the Key
Point is “how tight”—a matter of “feel”.
When using a knife, the Key Point is to “cut away from you.”
Don’t cut towards yourself.
When tightening a screw, if you turn down on it too hard
you will strip the screw threads. If you don’t turn down on
it hard enough, the screw may come loose. How much
power to put into the turn will be the Key Point.
EXAMPLES OF KEY POINTS
T H E W O R K S H O P S E R I E S

21. When diluting sulfuric acid, you have to gradually
pour acid into the water. If the order is reversed, the
acid and water may splash back and injure the
worker.
When assembling plastic components, hearing a
‘snap’ sound will tell you that the pieces are properly
connected.
EXAMPLES OF KEY POINTS (CONT)
T H E W O R K S H O P S E R I E S

22. Virginia Mason Medical Center, Seattle WA
80% of staff was trained in the new JI hand
washing method.
467 RNs and PCTs were taught 3 strategic
jobs in 9 weeks.
Hand Hygiene reliability went from 83.5%
use (as low as 40% worldwide) to > 98%.
HAND WASHING PILOT
T H E W O R K S H O P S E R I E S

23. T H E W O R K S H O P S E R I E S
JOB BREAKDOWN SHEET
DATE: January 21, 2008 TEAM LEADER: Donna S., Gillain A., Joan C. SPONSOR: Donna S., MD
AREA: All areas providing direct
pt care or in contact with pt care
supplies, equipment or food
JOB: Hand Hygiene in compliance with CDC & WHO
hand hygiene guidelines
WRITTEN BY: Joan C.
MAJOR STEPS KEY POINTS REASONS FOR KEY POINTS
Step #1: Identify the need for
clean hands
Remove artificial fingernails or extenders when in
direct contact with pts or their environment
Artificial nails house germs that can be passed on when you touch
pts
Clean hands whether or not you use gloves (i.e. before
putting on gloves & after removing gloves)
Gloves are not a substitute for cleaning hands because gloves
don't completely prevent germ transmission
Before direct contact with pt, pt's environment or
equipment
Protect the pt against harmful germs carried on your hands
After direct contact with pt, pt's environment or
equipment
Protect yourself & the health-care environment from harmful pt
germs
Step #2: Inspect your hands to
determine best cleaning
method
If not visibly soiled, use alcohol-based gel Cleaning with gel is faster, more effective, and better tolerated by
your hands
Visibly soiled hands or hand with fecal contamination
require washing with soap & water
Dirt, blood, feces or other body fluids are best removed with soap
& water (C. diff spores are not killed with alcohol-based gel)
Step #3: Use enough product to
cover all hand surfaces &
fingers
GEL: Cover all surfaces with a thumb nail-sized amount
Friction & skin contact are required to remove germs
WASH: Wet hands with water, wash with enough soap
to cover all hand/finger surfaces
Step #4: Spend enough time
cleaning your hands
GEL: Vigorously rub until product dries on your hands
Antiseptic action is not complete until fully dried (approx 15 sec.)
WASH: A minimum of 15 sec. (the length of singing
"Happy Birthday to You")
As least 15 sec. is needed to ensure complete coverage of hand
surfaces
Use paper towel to turn off water faucet
Prevent transfer of germs from faucet onto clean hands
Step #5: Let your hands
completely dry
Moisturize hands with lotion available through Central
Supply
To minimize contact dermatitis without interfering with
antimicrobial action
Put on gloves after hands are dry Skin irritation may occur if moist hands come in contact with glove
material
Step #6: Perform task with
clean hands
Task is done immediately after cleaning hands You may be distracted & touch unclean surface with clean hands

24. T H E W O R K S H O P S E R I E S
IMPORTANT STEPS KEY POINTS REASONS
A logical segment of the
operation when something
happens to advance the work.
Anything in a step that might—
1. Make or break the job
2. Injure the worker
3. Make the work easier to do, i.e.
“knack”, “trick”, special timing,
bit of special information
Reasons for the key points
1.Wet hands Without soap Soap rinses away
2. Apply soap Cover all surfaces Kill all germs
3. Rub hands
1. Palm to palm
2. Palm to backs
1. Clean entire surface
2. Clean entire surface
4. Run fingers
1. Thumbs
2. Interlocking
3. Backs of fingers to palm
4. Tips of fingers to palm
1. Most active part of hands
2. Sides of fingers cleaned at one time
3. Cuticles and knuckles
4. Under finger nails
5. Rinse hands Leave water on Prevent recontamination of hands
6. Dry Use towel to turn off water 1. Prevent recontamination of hands
BREAKDOWN SHEET AFTER TWI TRAINING

25. T H E W O R K S H O P S E R I E S
BREAKDOWN PRACTICE

26. IMPORTANT STEPS KEY POINTS REASONS
T H E W O R K S H O P S E R I E S
BREAKDOWN OF PUTTING ON STERILE GLOVES

27. IMPORTANT STEPS KEY POINTS REASONS
T H E W O R K S H O P S E R I E S
BREAKDOWN OF PUTTING ON STERILE GLOVES
1. Open Package

28. IMPORTANT STEPS KEY POINTS REASONS
T H E W O R K S H O P S E R I E S
BREAKDOWN OF PUTTING ON STERILE GLOVES
1. Open Package
2. Glove dominant hand

29. IMPORTANT STEPS KEY POINTS REASONS
T H E W O R K S H O P S E R I E S
BREAKDOWN OF PUTTING ON STERILE GLOVES
1. Open Package
2. Glove dominant hand
3. Glove other hand

30. IMPORTANT STEPS KEY POINTS REASONS
T H E W O R K S H O P S E R I E S
BREAKDOWN OF PUTTING ON STERILE GLOVES
1. Open Package
2. Glove dominant hand
3. Glove other hand
4. Adjust fit

31. IMPORTANT STEPS KEY POINTS REASONS
T H E W O R K S H O P S E R I E S
BREAKDOWN OF PUTTING ON STERILE GLOVES
1. Open Package
2. Glove dominant hand
3. Glove other hand
4. Adjust fit
1. Folding back creases 1. So pack lays flat on table

32. IMPORTANT STEPS KEY POINTS REASONS
T H E W O R K S H O P S E R I E S
BREAKDOWN OF PUTTING ON STERILE GLOVES
1. Open Package
2. Glove dominant hand
3. Glove other hand
4. Adjust fit
1. Folding back creases 1. So pack lays flat on table
2. Touching only outer edges 2. Maintain sterile field

33. IMPORTANT STEPS KEY POINTS REASONS
T H E W O R K S H O P S E R I E S
BREAKDOWN OF PUTTING ON STERILE GLOVES
1. Open Package
2. Glove dominant hand
3. Glove other hand
4. Adjust fit
1. Folding back creases 1. So pack lays flat on table
2. Touching only outer edges
3. Don’t lean over field
2. Maintain sterile field
3. Contaminants fall on field

34. IMPORTANT STEPS KEY POINTS REASONS
T H E W O R K S H O P S E R I E S
BREAKDOWN OF PUTTING ON STERILE GLOVES
1. Open Package
2. Glove dominant hand
3. Glove other hand
4. Adjust fit
1. Folding back creases
1. Pinching cuff
1. So pack lays flat on table
1.Keep sterile surface clean
2. Touching only outer edges
3. Don’t lean over field
2. Maintain sterile field
3. Contaminants fall on field

35. IMPORTANT STEPS KEY POINTS REASONS
T H E W O R K S H O P S E R I E S
BREAKDOWN OF PUTTING ON STERILE GLOVES
1. Open Package
2. Glove dominant hand
3. Glove other hand
4. Adjust fit
1. Folding back creases
1. Pinching cuff
1. So pack lays flat on table
1.Keep sterile surface clean
2. Touching only outer edges
3. Don’t lean over field
2. Maintain sterile field
3. Contaminants fall on field
2. Lift off paper 2. Keep hands off table

36. IMPORTANT STEPS KEY POINTS REASONS
T H E W O R K S H O P S E R I E S
BREAKDOWN OF PUTTING ON STERILE GLOVES
1. Open Package
2. Glove dominant hand
3. Glove other hand
4. Adjust fit
1. Folding back creases
1. Pinching cuff
1. So pack lays flat on table
1.Keep sterile surface clean
2. Touching only outer edges
3. Don’t lean over field
2. Maintain sterile field
3. Contaminants fall on field
2. Lift off paper
3. Tuck thumb
2. Keep hands off table
3. Hand slips in easily

37. IMPORTANT STEPS KEY POINTS REASONS
T H E W O R K S H O P S E R I E S
BREAKDOWN OF PUTTING ON STERILE GLOVES
1. Open Package
2. Glove dominant hand
3. Glove other hand
4. Adjust fit
1. Folding back creases
1. Pinching cuff
1. Sliding fingers in cuff
1. So pack lays flat on table
1.Keep sterile surface clean
1. Keep glove sterile
2. Touching only outer edges
3. Don’t lean over field
2. Maintain sterile field
3. Contaminants fall on field
2. Lift off paper
3. Tuck thumb
2. Keep hands off table
3. Hand slips in easily

38. IMPORTANT STEPS KEY POINTS REASONS
T H E W O R K S H O P S E R I E S
BREAKDOWN OF PUTTING ON STERILE GLOVES
1. Open Package
2. Glove dominant hand
3. Glove other hand
4. Adjust fit
1. Folding back creases
1. Pinching cuff
1. Sliding fingers in cuff
1. So pack lays flat on table
1.Keep sterile surface clean
1. Keep glove sterile
2. Touching only outer edges
3. Don’t lean over field
2. Maintain sterile field
3. Contaminants fall on field
2. Lift off paper
3. Tuck thumb
2. Keep hands off table
3. Hand slips in easily
2. Lift off paper 2. Keep hands off table

39. IMPORTANT STEPS KEY POINTS REASONS
T H E W O R K S H O P S E R I E S
BREAKDOWN OF PUTTING ON STERILE GLOVES
1. Open Package
2. Glove dominant hand
3. Glove other hand
4. Adjust fit
1. Folding back creases
1. Pinching cuff
1. Sliding fingers in cuff
1. Interlocking fingers
1. So pack lays flat on table
1.Keep sterile surface clean
1. Keep glove sterile
1. Tight fit on fingers
2. Touching only outer edges
3. Don’t lean over field
2. Maintain sterile field
3. Contaminants fall on field
2. Lift off paper
3. Tuck thumb
2. Keep hands off table
3. Hand slips in easily
2. Lift off paper 2. Keep hands off table

40. IMPORTANT STEPS KEY POINTS REASONS
T H E W O R K S H O P S E R I E S
BREAKDOWN OF PUTTING ON STERILE GLOVES
1. Open Package
2. Glove dominant hand
3. Glove other hand
4. Adjust fit
1. Folding back creases
1. Pinching cuff
1. Sliding fingers in cuff
1. Interlocking fingers
1. So pack lays flat on table
1.Keep sterile surface clean
1. Keep glove sterile
1. Tight fit on fingers
2. Touching only outer edges
3. Don’t lean over field
2. Maintain sterile field
3. Contaminants fall on field
2. Lift off paper
3. Tuck thumb
2. Keep hands off table
3. Hand slips in easily
2. Lift off paper 2. Keep hands off table
2. Pinch & Pull 2. No bubbles or folds

41. T H E W O R K S H O P S E R I E S
No. ________
JOB INSTRUCTION BREAKDOWN SHEET
Operation: __CD Case Assembly____________________________________
Parts: _Case, Tray, CD, Tray Card, Booklet____________________________
Tools & Materials: _None____________________________________________
IMPORTANT STEPS KEY POINTS REASONS
A logical segment of the operation
when something happens to advance
the work.
Anything in a step that might –
1. Make or break the job
2. Injure the worker
3. Make the work easier to do, i.e.
“knack”, “trick’, special timing, bit
of special information
Reasons for key points
1. Insert tray card
1. Right side up
2. Just breaking crease
1. Customer won’t buy it
2. Maintain outward pressure
preventing edge from being
crushed under tray
2. Insert tray
1. Sliding in from bottom
2. Hearing 2 snaps
1. So ribs of tray don’t cut
paper
2. Ensure fully seated into
case
3. Put CD on tray
1. Holding by edges
2. Pushing down in
center
1. No fingerprints on CD
2. Ensure fully seated on
spindle; no fingerprints
4. Insert booklet and
close
1. Right side up
2. Under all tabs
3. Tapping down
1. Customer won’t buy it
2. Unsightly; booklet crunches
beneath tab
3. Ensure closed completely
BREAKDOWN
EXAMPLE 1

42. No. __________
JOB INSTRUCTION BREAKDOWN SHEET
Operation: Glost Kiln Operator Cycle
Parts: None
Tools & Materials: Kiln Gloves
IMPORTANT STEPS KEY POINTS REASONS
A logical segment of
the operation when
something happens to
advance the work.
Anything in a step that
might—
1.Make or break the job
2.Injure the worker
3.Make the work easier
to do, i.e. “knack”,
“trick”, special timing,
bit of special
information
Reasons for the key
points
1.Discharge GK #3
1.Use kiln gloves
2.Pull at correct time
1.Burn hazard
2.Kiln control
2.Charge GK #3
1.Fix downed ware
2.Do not slam transfer
1.Defect prevention
2.Defect prevention
3.Record car data
4.Check kiln temperatures
1.Call Ceramic Tech if 50°F
delta in zones
1.Proper kiln control
5.Charge GK #3
1.Fix downed ware
2.Do not slam transfer
1.Defect prevention
2.Defect prevention
6.Discharge GK #3
1.Use kiln gloves
2.Pull at correct time
1.Burn hazard
2.Kiln control
7.Record car data
8.Check kiln temperatures
1.Call Ceramic Tech if 50°F
delta in zones
1.Proper kiln control
T H E W O R K S H O P S E R I E S
BREAKDOWN EXAMPLE 2

43. 1.A logical segment of the operation that advances the job
2.Some segments may be Important Steps even if the job has not
advanced
3.Both body movement and mental activity can be regarded as
Important Steps
4.Consider the learner’s ability when breaking down the job
5.Each Important Step should be balanced in terms of volume of
work
WHAT IS AN IMPORTANT STEP?
T H E W O R K S H O P S E R I E S

44. 6.Treat all parts of the operation equally
7.Break down operations that are embedded in jobs that have been
trained before
8.Create symmetrical breakdowns where possible
9.“Inspection” and “Measurement” items are also Important Steps
10.If there are many parts involved in an operation, the first step could be
an explanation of the parts
11.Do NOT include Important Steps like “Hold the ______” or “Get ready
to _______.”
WHAT IS AN IMPORTANT STEP?
T H E W O R K S H O P S E R I E S

45. 1.In principle, use the active voice
2.Stick to facts and be as accurate as possible
3.Make them as simple as possible
4.Make them as concrete as possible
5.Use expressions that describe the actual work to be done
HOW TO WRITE IMPORTANT STEPS
T H E W O R K S H O P S E R I E S

46. 6.Use expressions that describe either the operator’s motion or
the condition of the object being worked on
7.Don’t chop up long expressions artificially
8.Be careful when using only a verb
9.Don’t let an Important Step be the same expression as the
Operation Name
HOW TO WRITE IMPORTANT STEPS
T H E W O R K S H O P S E R I E S

47. 1. Points that are extremely difficult
2. Based on experience from past instruction:
A) Points that new workers fail to do.
B) Points that new workers misunderstand.
C) Points that all learners find difficult to remember.
D) Points that all learners do not easily acquire.
WHAT IS A KEY POINT?
T H E W O R K S H O P S E R I E S

48. 6.Points around which rules and standards are made
7. Procedures that must be followed when doing a job. They will
be key in doing the job correctly
8. Safety rules which must be followed. On this point, even small
items will be Key Points
9. Feel, knack, trick, timing, tact, or any small bit of knowledge
that gets the job done right
WHAT IS A KEY POINT?
T H E W O R K S H O P S E R I E S

49. 1. In principle, do NOT use verbs
2.If there are several Key Points in a single step, list them in order
of the actual operation
3.Be as specific as possible
4.Wherever possible, avoid using negative expressions
HOW TO WRITE KEY POINTS
T H E W O R K S H O P S E R I E S

50. 6.Key Points are sometimes impossible to express in words
7.Key Points sometimes need to express the degree of force used
in an operation
8.Key Points common to all steps should be written in the top spot
HOW TO WRITE KEY POINTS
T H E W O R K S H O P S E R I E S

51. Mexico
Monterrey
Lead factory
packing
Denmark
Billund
Lead factory
molding
Czech Republic
Kladno
Lead factory
processing
Hungary
Nyíregyháza
Lead factory
DUPLO
China
Shanghai
Newest factory
LEGO TRAINING AROUND THE WORLD
T H E W O R K S H O P S E R I E S

52. LEGO GLOBAL
TRAINING
ORGANIZATION
T H E W O R K S H O P S E R I E S

53. DEVELOPMENT
OF WORK STANDARDS
T H E W O R K S H O P S E R I E S
Process
1. Define important steps, key points and reasons while doing the
job at machine
2. Test the job breakdown by doing the training
3. Adjust the job breakdown
4. Continue until the job breakdown is place
5. Approval of job breakdown
a. Perform job for relevant stakeholders
b. e.g. Safety, Quality, Leaders, LEAN/LCI
6. Adjust the job breakdown
7. Train!

54. T H E W O R K S H O P S E R I E S
ROLES IN THE
JOB TRAINING
ORGANIZATION

55. The TWI Workbook: Essential Skills for Supervisors
Productivity Press, Shingo Prize 2007
Patrick Graupp and Robert J. Wrona
RESOURCES
T H E W O R K S H O P S E R I E S
Implementing TWI: Creating and Managing a Skills
Based Culture
CRC Press, October 2010
Patrick Graupp and Robert J. Wrona

56. Getting to Standard Work in Health Care: Using TWI
to Create a Foundation for Quality Care
CRC Press, October 2012
Patrick Graupp and Martha Purrier
RESOURCES
T H E W O R K S H O P S E R I E S
Building a Global Learning Organization: Using TWI to
Succeed with Strategic Workforce Expansion in the
LEGO Group
CRC Press, June 2014
Patrick Graupp, Gitte Jakobsen & John Vellema

57. PATRICK GRAUPP
PGRAUPP@TWI-INSTITUTE.ORG