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Training Within Industry (TWI) is a Leadership Development Program designed to provide supervisors and team leaders with the ability to: lead, Instruct, Train and Improve their jobs method.
Applicable to any industries including:
Training Within Industry (TWI) is a proven methodology developed in the USA and later brought to Japan. It’s known to be the underlying set of methods used to transform Toyota together with the Toyota Production System.
Teaches how to continuously improve the way the job is done
Teaches how to train employees quickly,how to do a job correctly and with understanding
Teaches essential leadership skills to relate with subordinates and handle people's problems
How Training Within Industry (TWI) helps business and organisation improve their productivities
Large MNC corporations in Malaysia and China were facing significant challenges in managing their complex operations, including lengthy training periods for new operators to gain specialized skills, non-standard work methods leading to quality issues, poor supervisor-employee relationships causing high turnover rates, and suboptimal work processes. With over 8,000 employees at each site, there was a need for an efficient and effective solution to manage these challenges.
To overcome these challenges and achieve greater efficiency and cost savings, our team provided a 4-month training program on TWI Job Method Improvement, Job Instructions, and Job Relations, coaching several teams in two different sites. Additionally, we conducted a 3-month Train the Trainer program to skill up in-house TWI experts and practitioners.
Through our Lean solutions, we were able to achieve remarkable results. Our interventions ensured that the actual work now complies with SOP by 98%, significantly reducing quality problems caused by non-standard work methods. By eliminating 50% of non-value-adding steps in work processes, we were able to reduce the training and skilling time by 40% for the corporation. Overall, the project has generated cost savings estimated at USD3,000,000 for both sites.
Our Lean solutions have transformed the operations of the MNC corporations, ensuring that they are more efficient, effective, and profitable. Our focus on Lean methodology has helped the corporations to streamline their operations, improve their work processes, and achieve significant cost savings. At Lean Asia, we are committed to providing our clients with the best Lean solutions to transform their operations and help them achieve their business goals. Contact us today to learn more about how we can help your business achieve greater efficiency and cost savings.
A large manufacturing company supplying to the aerospace industry in China was facing a critical challenge of high turnover rates and long training periods required to meet the specialized skill set necessary for industry standards. This had led to a significant shortage of skilled workers and was affecting the company's ability to meet production demands and maintain quality standards.
The results were remarkable. Our interventions led to significant reductions of 40% in training and skilling time, and a 50% reduction in turnover rates. The company was able to retain more skilled workers, meet production demands, and maintain high-quality standards. The total estimated savings in productivity and training time for the company were estimated to be USD 9,000,000.
Our focus on Lean methodology and TWI solutions has helped the company streamline their operations, improve their work processes, and achieve significant cost savings. At Lean Asia, we are committed to providing our clients with the best Lean solutions to transform their operations and help them achieve their business goals. Contact us today to learn more about how we can help your business improve productivity and profitability.