TWI
101: Overview of TWI and the "J" Programs
TWI Institute Master Trainer Patrick Graupp
and TWI Institute's Dick Jackson
In the Toyota Way Fieldbook, Jeffrey Liker and David
Meier state, “The Toyota method for training is tried
and true, and they have used it (Training Within
Industry - TWI) for over 50 years.” This workshop will
explain TWI from the time it was created during WWII,
the impact it had on the outcome of that war, why TWI
was dropped in the US after the war only to end up in
Japan where the program became a cornerstone of the
“Japanese industrial miracle” known as Kaizen. A
detailed overview of the three “J” components of Job
Relations (JR), Job Instruction (JI), and Job Methods
Improvement (JM) will focus on the 4-step method common
to all three programs. A hands-on demonstration of the
JI program will remove any doubts about why the TWI
4-step training method has not changed in over 60 years,
even at Toyota. You will learn how JR can create a
positive work environment, how JI provides a sure way to
train a person providing a foundation for standard work,
and how JM involves the people who do the work to
continuously improve. Those attending will also walk
away from this workshop with a clear understand about
why TWI is referred to today as “the missing link to
lean.”
Workshop Fee: $375
Select this workshop when registering for the
Summit.
Patrick Graupp, Senior
Master Trainer, TWI Institute
Patrick began his training career at the SANYO Electric
Corporate Training Center in Japan after graduating with
Highest Honors from Drexel University in 1980. There he
learned to deliver TWI and other training to prepare
employees for assignment outside of Japan. He in turn was
also transferred to a compact disc fabrication plant in
Indiana where he obtained manufacturing experience before
returning to Japan to become Programs Master Trainer
delivering TWI around the world for Sanyo. Patrick earned an
MBA from Boston University during this time and later
published a book on how to teach Japanese staff to implement
Job Methods Training outside of Japan. He was then promoted
to the head of Human Resources for SANYO North America Corp.
in San Diego, CA where he settled.
Patrick took vacation time to deliver a pilot project
for CNYTDO in 2001 to reintroduce TWI in the US, and again
in 2002 to reintroduce the full TWI Program at ESCO Turbine
Technologies-Syracuse. The results at ESCO encouraged Pat to
leave SANYO in 2002 and work with CNYTDO to deliver and
document how to deliver the TWI program in the US as he was
taught in Japan. Pat also describes this process in his book
The TWI Workbook: Essential Skills for Supervisors, a Shingo
Research and Professional Publication Prize Recipient for
2007. These standardized training manuals and materials are
now used by the TWI Institute to train and certify trainers
on how to deliver JR, JI and JM as was done by the TWI
Service during WWII. Patrick also documented the format on
how he was trained as a TWI Master Trainer (trainer of
trainers) in Japan as he trained two new TWI Master Trainers
for TWI Institute. TWI is now readily available nationally
in English and in Spanish from the TWI Institute for
companies to learn how Toyota trains new employees to
strictly adhere to standardized operations and as a review
of parts of the training system to enable quick learning to
sustain TPS.
Dick Jackson,
TWI Program Specialist
Dick began his manufacturing career at Remington Arms
Company in Ilion, NY as a machine operator. Since 1982 Dick
was employed in various management positions at Remington
that included Quality Engineer, Engineering Supervisor,
Organization Development Resource, and as the Group Leader
of the Continuous Improvement Group.
He left Remington in 1996 to become Vice President and
eventually President of Revival Industries in Herkimer, NY
where he directed all daily activities as the majority owner
until 2007. Dick then looked to put his experience to work
as a Lean consultant helping local manufacturers as they
struggled to compete in the global market. This work led him
to the discovery of the TWI Program and he became a TWI
Institute Certified Trainer for JI, JR, and JM in 2008. Dick
has since delivered numerous TWI training classes and
implementation consulting at companies around the globe for
the TWI Institute. His strong engineering and management
experiences are now put to good use when introducing TWI to
companies and when providing follow-on coaching for the
implementation process.
Dick received an AS Engineering Science degree from
Mohawk Valley Community College and then continued his
education in night school at Syracuse University where he
earned a BS Mechanical Engineering and a Master of Business
Administration.
