Table Of ContentLean Methods & Implementation / Organizational Culture
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“One must learn by doing the thing; for though you think you know it, you have no i
n
certainty until you try it.” e
r
—Sophocles o
TWI Case Studies: Standard Work, Continuous Improvement, and Teamwork
provides the insight of leading experts to assist in the execution of Training Within Industry
(TWI)—the game-changing business tool. Presented as a series of case studies from a
range of corporations with a variety of products and needs, it illustrates the rebirth of TWI
programs in the United States.
Demonstrating how TWI can benefit any and all organizations regardless of industry, the
book details the specific activities decision-makers need to accomplish to successfully
incorporate TWI into the business culture—including the Ten Points for Implementing and
T
Sustaining the TWI “J” Programs. The case studies describe the use of TWI Programs at
W
some of the world’s leading companies, including:
• IBM I
• Herman Miller C
• Ben & Jerry’s Homemade Ice Cream a
s
• Green Mountain Coffee Roasters
e
• US Synthetic
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t
Born in the 1940s, and used to support the US military during World War II, TWI Programs
u
later became the unrecognized yet powerful tools of the Toyota Production System. d
Imparting the fundamental skills that are useful across any field, the TWI programs i
e
described in this book are so fundamentally sound that using them to any degree will s
improve performance. Strict adherence will all but guarantee efficient work flow, higher
employee morale, and an improved sense of cohesiveness among your employees.
K12063
ISBN: 978-1-4398-4610-0
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K12063 cvr mech.indd 1 3/17/11 2:31 PM
TWI Case
Studies
Standard Work,
Continuous Improvement,
and Teamwork
TWI Case
Studies
Standard Work,
Continuous Improvement,
and Teamwork
Donald A. Dinero
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2011 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Version Date: 20110720
International Standard Book Number-13: 978-1-4398-9124-7 (eBook - PDF)
This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to
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To my wife, Maureen,
who continues to be my muse and main support.
Contents
Acknowledgments............................................................................. xi
Introduction....................................................................................xiii
1 Use.and.Misuse.............................................................................1
Reasons for Lack of Success .......................................................................2
Lack of Commitment ...........................................................................2
Unforeseen Circumstances ..................................................................3
Underestimating the Required Effort ..................................................4
Insufficient Experience .......................................................................5
Principal Reason for Lack of Success .........................................................5
The Path to Success ....................................................................................6
2 A.Variety.of.Improvements...........................................................9
Great Gains—Focused Application ..........................................................10
Garment Manufacturing ............................................................................10
Aircraft Manufacturing ..............................................................................11
JIT: “The Acid Test”—Mabati Rolling Mills, Mombasa, Kenya ................12
Standard Training and Standard Work Support Growth—The U.S.
Synthetic Company ...................................................................................14
The Power of Standard Work and Its Importance in a Regulated
Company—The Autumn Harp Company .................................................18
Results........................................................................................................22
What Was Done Right ..............................................................................23
What Could Have Been Done Differently ...............................................24
Improvements After 120 Years—The Ludowici Roof Tile Company ......25
Implementation and Use ...........................................................................26
The Use of Job Relations Training—The Rhino Foods Company ..........27
An Urgent Need for Job Relations Training .............................................29
vii
viii ◾ Contents
3 Green.Mountain.Coffee.Roasters—Continuous.Growth.............31
Introduction ...............................................................................................31
Purpose .....................................................................................................32
Implementation and Use ...........................................................................33
Keurig Lines ..............................................................................................34
WIP Areas .................................................................................................36
Benefits ......................................................................................................37
Done Well and Opportunities for Improvement .....................................38
Conclusion .................................................................................................39
4 IBM—A.Revival...........................................................................41
The Reintroduction of TWI at IBM ..........................................................43
Quantifying Benefits .................................................................................50
Sustaining TWI ..........................................................................................55
Problem‑Solving Structure ........................................................................58
JIT in the Supply Chain ............................................................................61
5 Ben.&.Jerry’s.Homemade.Ice.Cream—A.Tale.of.Two.Plants......63
Background ...............................................................................................63
The Beginning ..........................................................................................64
Becoming Trainers ....................................................................................65
Starting JIT at St. Albans ...........................................................................67
Integrating JIT with Existing Activities .....................................................67
What Can Be Learned ...............................................................................70
Publish Results ...................................................................................70
Creating JBSs .....................................................................................70
A TWI Champion ......................................................................................72
Training Institutes .....................................................................................74
Audits .........................................................................................................75
Other Results .............................................................................................76
6 Herman.Miller—How.Lean.Are.You?..........................................77
Company ...................................................................................................77
Herman Miller’s Journey into Lean ..........................................................78
The Need for TWI Job Instruction ...........................................................81
An Approach to Develop Job Instruction ................................................84
Results and Learning .................................................................................89
Contents ◾ ix
Case.Study.Sources............................................................................95
Bibliography......................................................................................97
About.the.Author.............................................................................107
