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MasteryGrowth of the student
The student determines how far they will travel along the path.
10-Hour Sessions = Beginner Level
Learn the patterns
Practice one example
Learning the Patterns
Image is from the movie “The Last Samurai”
Training Coaches with Legos
Teams of Three – discussion on how to assemble in a production environmentOpen discussions as they develop a 1-best-way, experimenting and developing understanding.
Builds thinking for when they do their first JBS on the shop floor on a task to improve.Understanding the how’s and why’s of the JI, JR and JM patterns.
KataPracticing the patterns to grow skills
JBS LayersSimplest application of covering materials the trainer knew.
Top level breakdown defined four important steps.
Trim Cubby Door
Inspect Surfaces
Mask Metal Apply Cover Materials
Apply Glue
Butt Joint Corner Joint
1 Important Step
4 Important Steps
3 Important Steps
9 Important Steps
The ‘simple’ job had far more details than the trainer’s first realized. As we observed and detailed each breakdown, they could see how some complex steps needed individual JBS done for training.
In detailing the JBS, the trainer’s realized that many places they just relied on operators' skills could be made easier with simpler fixtures. The trainer stayed over in the evenings to make the fixtures. This changed a 3 ½ hour job into 45 minutes. They also had many more ideas to simplify the task.
Trainer’s practice JBS
Blending the Patterns
Image is from the movie “The Last Samurai”
Using all the patterns together = Intermediate Level
First: used JI to define the tasks to be done
Second: used JR to solve problems identified
Third: used JM to challenge the current standard and develop improvements
Result: reduced staffing required by six people on the custom packaging lines
Explore the Boundaries
Job allocation
Name of Job Person A Person B
Compression Machine – Get Ready
Rows in blue Rows in white
Compression Machine – Assemble
Rows in blue
Rows in white & to support person A by handing the required tools/parts in sequence.
Name of Job: Compression Machine – Get Ready
WHAT Important Steps:
Logical sequence of steps which advance the work
HOW
Key Points: Make or break the job, make the job easier, can injure the worker
WHY Reasons: Explains the key points
Prepare machine room Fill in In-Process sticker before starting activities
Prepare granules for compression
Ensure all granule drums are transferred to the compression machine room
One batch number at a time Prevent mix up
One product at a time
Prepare tooling set (upper punch, die, lower punch)
Select per BMR according to product name and strength
Inspect to ensure clean
Prepare compression machine parts Transfer parts trolley to the compression machine room
Missing cap
JI – define standardJR – solve problemJM – propose solution
JI – define standards for two-person team on changeover (color code)
JI – define standards for all processes, from the get ready steps, to changeover, to operations, to clean-up
Food Packaging Pharmacy tablet machine Changeover processes
Developing Mastery
Remove the Mental Models of what you think lean looks like.Focus on the process – the here and now!
Images are from the movie “The Silent Warrior”
Take out the Trash
"Any sufficiently advanced technology is indistinguishable from magic." - Arthur C. Clarke
is a lifelong journey
Masters at worklooks like magic
Toyota’s support of a raincoat manufacturer to develop PPE for the pandemic response effort.
If you were not knowledgeable of TWI, you would not be able to detect where they applied the skills.
The masters went to the shop floor to learn knowledge of the work before developing standards and improving the processes.
From 500 a day to 10,000https://www.linkedin.com/pulse/toyotas-rapid-application-tps-mark-warren/
You can’t learn when you think you already know.
requires becoming a student again
Mastery
Resources
1973 Toyota Production System Manual
Job Instruction 10-hour Sessions Outline
Trainer’s Guide
Reprints of many more TWI materials [email protected]
