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Training Within Industry: Problem Solving
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Training Within Industry is the structural genesis of Lean Manufacturing and the heart of kaizen, the practice of small continuous improvements. From the Toyota Production System to the standardization of training retail sales clerks, Training Within Industry proves that true innovation is timeless. The training material contained in this 8 1/2 x 11″, 118 page Training Within Industry book is as applicable today as it was when it was first written down, decades ago.
The Problem Solving Training Program coaches on how to properly isolate, break down, question, and solve problems, while giving insight to the responsibilities of supervisors in general. It is just as important for a person to be able to identify a possible problem as it is to solve the problem. Through the use of this book you will learn:
- How to spot a problem
- The duties and responsibilities of supervisors
- Ways to isolate and breakdown a problem
- How to more effectively come up with solutions
By teaching the skills needed not only to solve problems, but to properly identify them, T.W.I.’s Problem Solving Training book strives to create a more dynamic, dependable and self-reliant work force. The guidance written out along with the charts and breakdown sheets to supplement visual learning, and the sample problems faced, make this book an interesting and thought provoking learning tool.
- ISBN: 978-1926537009
- Page Count: 116
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Mistaken Kanbans – Why the Toyota System is Not Working for You
Organizing for Work, by Gantt
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Training Within Industry: Bulletin Series
Training Within Industry: Job Instruction
Training Within Industry: Job Relations
Training Within Industry: Program Development
Twelve Keys to Sustainable Company Success
Value Stream & Process Mapping Book
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TWI Training and Coaching
What is training within industry (twi).
Training Within Industry (TWI) is a dynamic and proven method of hands-on training, learning and coaching for supervisors, team leaders, and workers.
TWI was introduced in 1940 by the United States Department of War and operated within the War Manpower Commission until 1945. It was originally developed to meet the high demand for wartime materials from a smaller and less-experienced workforce.
Today, training within industry remains relevant because of its unique methodology that empowers the frontline.
TWI training is practical and fundamental; its benefits transcend time, place and situation.
- Can be learned and applied by itself or in conjunction with other problem solving and improvement programs
- Builds skills, stability, safety and confidence
- Develops frontline people as the engine for sustainable results in the workplace
- Creates an essential foundation for problem solving, standard work, continuous improvement, operational excellence and Lean initiatives
- Encourages positive employee relations, resolves conflicts, increases cooperation and motivation
Let’s Talk TWI
Why the TWI training method is effective
Your people become involved and feel appreciated; their performance and emotional commitment takes productivity to new heights. Through TWI training, supervisors learn to instruct, improve methods and lead people effectively.
Learn by Doing
The TWI training method emphasizes step-by-step instruction, practice and coaching. Learners aren’t just observers, they’re doers.
The expertise your team learns sticks with them, leading to process consistency, stability and better, more efficient teamwork.
Aligned with Goals
Before any training begins, we work with you to understand what you need to accomplish and set target metrics accordingly.
Job instruction (ji), job relations (jr), job methods (jm), job safety (js), twi problem solving (ps), skillpoint for ji, what our clients say.
The value of TWI Institute and its certified teachers and coaches is in making manuals and materials come alive in the hands, the mind, and the workplace. David Hyem, Vice President of Metal Fabrication (Retired) From Boeing David Hyem, Boeing, Value of TWI (TWI Training, Transportation page, and Why TWI page)
Become a certified TWI trainer
Remember how much you enjoyed your favorite teacher? Great teachers turn a learning process into an enriching experience. If you love the idea of inspiring people, helping them improve and watching them grow with a sense of accomplishment and self-satisfaction, then becoming an internal certified TWI trainer for your employer can be a rewarding adjunct to your career, or the beginning of a new one.
TWI Training Resources
We cannot afford to hurry: training within industry applied to nursing, toyota kata programs - a complete system for putting kata into practice, ready to get started.
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Training Within Industry
Buku tentang Training Withing Industry, terutama TWI-Job Instruction (JI). Suatu jenis training yang langka di Indonesia. TWI yang metodenya dirancang di Amerika Serikat menjadi salah satu alat bantu Amerika Serikat guna menang PD II. TWI juga menjadi salah satu alat bantu Jepang untuk bangkit dari keterpurukan karena hancur akibat pengeboman saat PD II. TWI juga salah satu alat Toyota (yang merupakan perusahaan manufaktur yang menjadi benchmark di dunia) untuk mengembangkan sayapnya. Dalam TWI seorang Supervisor (orang yang dititipkan seseorang untuk dididik) membutuhkan 5 prasyarat , mempunyai 2 Pengetahuan dan 3 Skill : 1. Pengetahuan tentang Pekerjaan 2. Pengetahuan tentang Tugas dan Tanggung Jawab 3. Skill Mengajar/memberikan instruksi 4. Skill Melakukan perbaikan 5. Skill Menangani orang/bawahan Skill Mengajar dirangkum dalam modul TWI-JI (Job Instruction), Skill Melakukan perbaikan dirangkum dalam modul TWI-JM (Job Method) Skill Menangani orang/bawahan dirangkum dalam modul TWI-JR (Job Relation). Buku ini adalah buku ke-1 yang menceritakan sejarah TWI dan membahas TWI-JI utamanya.
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Buku ini menjelaskan tentang sistem pendidikan dasar dan menengah di negara negara: Amerika Serikat, Arab Saudi, Australia, Belanda, Filipina, India, Inggris, Jepang, Jerman, Malaysia, Mesir, Papua New Guinea, Perancis, Singapura, Thailand, dan Tiongkok.
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Suyatno Suyatno , Yuni Sri Rahayu
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Marwah Aisyiyah Mawardhy
Sri Makmuri TKM
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Lean Events and Training / Forms and Templates
Forms and Templates
Downloads for A3 problem solving, standard work , project management, and value stream mapping .
Problem Solving Templates
A3 Action Plan Form (from Getting the Right Things Done)
- The action plan template helps define the who, what, when, where, and how of a plan on one page.
- Helps track progress and highlight problems so action can be taken.
A3 Status Review Form (from Getting the Right Things Done)
- Top box provides an overview with respect to our critical end-of-pipe metrics.
- Second box provides an overview of activities, and usually reflects what’s been prescribed on the action plan of the right side of the strategy A3.
A3 Strategy Form (from Getting the Right Things Done)
- A strategy A3 is a one-page storyboard on 11-inch by 17-inch paper that helps tell the strategy “story.”
- Logic flows from top left to bottom right, and each box leads to the next one.
Detailed A3 Template (from Managing to Learn)
- Print this A3 template out to remind you of each section of the problem-solving A3 as you are creating your own.
PDSA A3 Template (from On the Mend)
- A3 Template, in Excel, following the PDSA cycle.
Problem Definition Worksheet
- This worksheet can help you breakdown the problem into a clearly defined gap as well as see how the problem aligns to the needs of the business or your True North purpose.
Root Cause Template
- This template gives you space to record the problem as well as the direct causes and underlying causes.
Four Types of Problems
Managing to Learn: Using the A3 management process
Perfecting Patient Journeys
Beau Keyte , Tom Shuker and Judy Worth
Getting the Right Things Done
Standard Work Templates
Standard Work Operator Balance Chart (OBC)
- The operator balance chart helps create continuous flow in a multi-step, multi-operator process by distributing operator work elements in relation to takt time.
Standard Work Process Study Sheet
- The Process Study Sheet is used to define and record the time for work elements in a process.
Standard Work Production Analysis Board
- A Production Analysis Board is a display that must be located at the exit of the cell (or the line) to show actual performance compared with planned performance on an hourly basis.
Standard Work Skills Training Matrix
- The Skills Training Matrix shows the required and attained skills of every operator.
- The training schedule also should be shown.
Standardized Work Chart
- The standardized work chart shows operator movement and material location in relation to the machine and overall process layout.
- It should show takt time, work sequence, and standard WIP.
Standardized Work Combination Table
- The standardized work combination table shows the combination of manual work time, walk time, and machine processing time for each operation in a production sequence.
- This form is a more precise process design tool than the Operator Balance Chart.
- It can be very helpful to identify the waste of waiting and overburden, and to confirm standard.
Standardized Work Job Instruction Sheet
- The job instruction sheet is used to train new operations.
- It lists the steps of the job, detailing any special knack that may be required to perform the job safely with utmost quality and efficiency.
- It can also be useful for experienced operators to reconfirm the right operations.
Standardized Work Process Capacity Sheet
- The Process Capacity Chart is used to calculate the capacity of each machine to confirm true capacity and to identify and eliminate bottlenecks.
- Processing capacity per shift will be calculated from the available production time, completion time, and tool-change time (and other factors as necessary) for each work piece.
Waste Walk Template (from Perfecting Patient Journeys)
- Taking a “waste walk” is one way to make the waste visible again.
- A waste walk is simply a planned visit to where work is being performed to observe what’s happening and to note the waste. It differs from go-see activities in that you are specifically looking for waste.
Toshiko Narusawa and John Shook
Lean Lexicon 5th Edition
Lean Enterprise Institute
Training Within Industry (TWI) Templates and Downloads
8-step TWI problem solving card - as presented by IBM
- 8-steps to problem solving handy pocket card printable.
Solving Problems with TWI
- Solving problems with TWI deployment graphic.
Template of Job Breakdown Sheet
- Job breakdown sheets are created to list the steps and highlight the main factors or key points that go into completing a job.
- It also provides reasons for these key points.
TWI Job Instruction Card
- TWI Job Instruction card in a handy pocket printable.
TWI Job Methods Card
- TWI Job Methods Card in a handy pocket printable.
TWI Job Relations Card
- TWI Job Relations Card in a handy pocket printable.
James (Jim) Womack, PhD and Dan Jones
Lean Thinking, 2nd Edition
Project Management Templates
Master Schedule and Action Plan Template for One Goal (from Perfecting Patient Journeys)
- Use this template in your project tracking center so you can track both goals and action items on the same form.
End of Project Review Template (from Perfecting Patient Journeys)
- The following template will help you capture your end-of-project reflections and make decisions about what to do next.
Master Schedule Template (from Perfecting Patient Journeys)
- This template will help you answer this question by letting you include the project goals with space to indicate whether each goal is on track as originally planned and whether the scheduled progress review has taken place.
Team Board Form (from Getting the Right Things Done)
- A team board is a window on both routine and improvement work.
- The board on this template addresses both daily production and strategic issues, and is organized according to SQDCM—safety, quality, delivery, cost, and morale.
Value Proposition Template (from Perfecting Patient Journeys)
- Align the stakeholders around what will be included in addressing the problem,
- Identify the stakeholders who will be added to the project team and actively engaged in creating the current- and future-state value-stream maps,
- Identify additional stakeholders necessary to drive the implementation of the future state,
- Serve as an agreement—a proof of consensus—on the specific problem to be solved, and with the problem statement serve as authorization for the entire project.
Action Planning Template (from Perfecting Patient Journeys)
- Identify the specific changes that need to be made and translate those changes into clearly stated goals and actions (i.e., the means) to achieve those goals.
- Identify the specific methods and action steps you think will help you achieve the goals. These action steps and targets constitute the action plan to achieve a specific goal.
Value-Stream Mapping Templates
Value-stream Mapping Icons for Excel
- At the request of some of our readers we have posted the most commonly used mapping icons so that they can be downloaded for Excel spreadsheets.
Learning to See
Mike Rother and John Shook
VSM Getting Started Set
Lean Enterprise Institute , Mike Rother and John Shook
Mapping to See: Value-Stream Improvement Workshop
Beau Keyte , Jim Luckman , Kirk Paluska , Guy Parsons , John Shook , Tom Shuker and David Verble
Improvement Kata / Coaching Kata
Improvement Kata Learner's Storyboard
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Training Within Industry
Training Within Industry (TWI) is a dynamic method of hands-on training, learning and coaching for supervisors, team leaders, and workers. TWI creates a foundation for problem-solving, standard work, continuous improvement, operational excellence and performance improvement initiatives. Implementation increases positive employee relations that increase cooperation and motivation for sustainable results in the workplace.
TWI Consists of Three Basic Tools:
Job instruction (ji).
Teaches how to quickly train employees to do a job correctly, safely, and conscientiously.
Immediate Results: Provides a methodology for standardization. Skills are taught faster, better, and more consistently from learner to learner.
Long-Term Results: Each time an instructor successfully trains a learner, trust is built. Individuals who trust each other communicate effectively and work as a team. The fear of failure is eliminated because individuals see the positive results and relationships.
Job Relations (JR)
Teaches how to build positive employee relations, and increase cooperation and motivation.
Immediate Results: Provides simple strategies for building cooperation. A 4-step approach is taught to handle issues resulting in the best possible outcome.
Long-Term Results: When individuals treat others fairly and with respect, positive relationships are developed through training. Fewer distractions that interfere with performance come from individuals modeling team-like behavior.
Job Methods (JM)
Teaches how to improve the way jobs are done.
Immediate Results: Provides a methodology to remove waste from processes for supervisors and operators. Without major disruptions to production, changes are made within their span of control to increase workflow with higher quality and safety.
Long-Term Results: Individuals are more likely to share their ideas for improvement as cohesiveness, trust, and abilities improve within the organization. Collaboration begins to take place and the fear of rejection or embarrassment decreases.
1. Top Management support/participation
- Management identifies goals and establishes metrics
- Management identifies a TWI Champion
- Line Management participation and ownership for metrics
- Reporting of metrics/recognition
- Periodic audits
2. Select pilot area for initial implementation*
- Select 8 to 10 participants (supervisors, lead people, anyone who has to show others how to do something)
- Participants attend 10 hours of training in Job Relations and 10 hours in Job Instruction (2-hour sessions)
3. Participants develop Job Breakdowns and train employees using Job Instruction
- Participants use Job Relations to address problems and improve relationships
- Audit to determine if improvements are sustained. (Do we have standard work?)
- 30/60 day follow-up/evaluation session
4. Once there is standard work, train participants in Job Methods 10-hour class*
- Use Job Methods to improve the processes and solve problems
- Audit to determine the effectiveness
- Continue to compare measurements (quality, turnaround time, employee satisfaction) to ensure continual improvement
*Alternative training sessions can be accommodated, for example, in greater or less than two-hour sessions (consecutively or non-consecutively).
Speak with one of our Improvement Specialists to customize your approach.
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Home » Blog » Leadership & Management » Problem-Solving in the Workplace Training Course Materials
Problem-Solving in the Workplace Training Course Materials
Page Updated on September 16, 2023
Our ‘Problem-Solving in the Workplace’ training course materials are for corporate trainers to run sessions on how to solve fairly complex problems at work. These materials are suitable to train leaders, managers, and employees at any level.
The materials guide the participants through a seven steps problem-solving process and introduce them to some useful techniques (some creative and some more analytical) they can apply to help them find solutions to their problems.
This training package is:
- Fully customizable and editable
- US English & British English compatible
- Downloadable immediately
- Can also be adapted to use for online teaching and training in virtual classrooms.
- and you will own the rights to edit and reuse it for as many of ‘ your own courses’ as you wish
Samples from the Training Materials
Click on the slides below to magnify
British GBP £127 (approx. USD$159)
Buy This Course
- To purchase click the “Buy Now” button below.
- You can choose to pay via PayPal or by Credit card.
- Once you have paid, you will immediately receive a digital link to download the zip file straight away.
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The Training within Industry Report 1940-1945
War Manpower Commission. 1945. “The Training within Industry Report 1940-1945.” War Manpower Commission., in public domain. Many thanks to Bryan Lund for scanning the original documents and making a PDF of this historic document.
- File Name: Training-Within-Industry-Report.pdf
- File type: pdf
- File size: 17.09 MB
- Date: January 7, 2018
- SEO Title: The Training within Industry Report 1940-1945
- SEO Description: War Manpower Commission. 1945. “The Training within Industry Report 1940-1945.” War Manpower Commission. Many thanks to Bryan Lund for scanning the original documents and making a PDF of this historic document.
- SEO Keywords: The Training within Industry Report 1940-1945, TWI