DESCRIPTION
 

The Training Within Industry (TWI) programs were developed by leading U.S. training and management experts and thoroughly field-tested before being widely adopted. Introduced to Japan in the 1950s, TWI gained strong traction among companies like Toyota for its practical approach and results.

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Now integral to Lean, TWI aims to build a skilled workforce, improve labor-management relations, boost productivity, enhance safety, and drive continuous improvement.

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This comprehensive training package includes five key TWI programs:

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• Job Instruction (JI): Trains supervisors to instruct workers on how to perform tasks correctly, safely, and efficiently, minimizing errors, rework, and damage.

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• Job Relations (JR): Equips supervisors with techniques to address personnel issues using a calm, structured, and human-centered approach.

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• Job Methods (JM): Focuses on improving job processes to consistently increase output and quality using existing resources.

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• Job Safety (JS): Teaches supervisors to identify and eliminate root causes of accidents, creating a safer work environment through proactive analysis.

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• Problem Solving (PS): Develops supervisors’ ability to solve problems effectively by integrating skills learned in JI, JM, and JR into a unified problem-solving approach.

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The training materials are customizable and designed for classroom and/or shopfloor use. Job aids such as Job Breakdown Sheets and Training Timetables are ready for immediate application or can be adapted to specific needs.

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Modules can be delivered independently, through 2-hour sessions, or tailored to fit your organization's operational requirements.

 

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LEARNING OBJECTIVES

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1. Job Instruction (JI):

Train supervisors to deliver clear, step-by-step instructions that help workers perform tasks safely, correctly, and efficiently from the start, reducing errors and waste.

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2. Job Relations (JR):

Develop supervisors' ability to handle personnel issues using a calm, analytical approach that fosters trust, respect, and effective teamwork.

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3. Job Methods (JM):

Teach supervisors how to evaluate and improve job processes to increase output and quality using existing people, materials, and equipment.

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4. Job Safety (JS):

Enable supervisors to identify, analyze, and eliminate potential hazards to prevent accidents and create a safer work environment.

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5. Problem Solving (PS):

Empower supervisors with a structured problem-solving method that integrates JI, JR, and JM skills to achieve consistent, effective results.

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CONTENTS

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1. Introduction to TWI

• Brief History of TWI

• TWI - The Missing Link to Lean & Kaizen

• What is TWI?

• Components of TWI

• Benefits of TWI

• TWI - A Timeless Approach

• The Four-step Method

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2. Five Needs of Good Supervisors

• Who is a Supervisor?

• Five Needs Model for Good Supervisors

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3. Job Instruction (JI)

• Four Steps for Job Instruction

• Four Steps to Get Ready

• Job Breakdown – Important Steps, Key Points & Reasons

• Training Timetables

• Special Instruction Problems

• Job Instruction & Standard Work

• Activities & Discussions

• Practice Demonstrations by Participants

 

4. Job Methods (JM)

• Four Steps for Job Methods Improvement

• Job Breakdown Sheet

• 5W1H

• Eliminate, Combine, Rearrange & Simplify

• Job Method Improvement Proposal Sheet

• Resistance & Resentment

• Activities & Discussions

• Practice Demonstrations by Participants

 

5. Job Relations (JR)

• Chart on Supervisory Responsibility

• Foundations for Good Relations

• Chart on the Individual

• How Problems Arise

• Four Steps for Job Relations

• How to Get Feelings & Opinions

• How to See Problems Coming

• Activities & Discussions

• Practice Demonstrations by Participants

 

6. Job Safety (JS)

• Definition of Safety Incident

• The Incident Chain

• Heinrich's Accident Pyramid

• Four Steps for Job Safety

• Job Safety Breakdown

• Job Safety Instruction

• How to Spot Hazards

• How to Avoid Hazards

• Three Rules for Making Safety Instructions

• Supervisor’s Major Safety Responsibilities

 

7. Problem Solving (PS)

• Introduction to Problem Solving

• Objective of Problem Solving

• What Is a Problem? 

• 4 Steps for Problem Solving

• Step 1: Isolate the Problem

• Step 2: Prepare for Solution

• Step 3: Correct the Problem

• Step 4: Check and Evaluate Results

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List of materials included in this comprehensive training package:

 

1. TWI Introduction & TWI Job Instruction PPT Training Presentation (PowerPoint format)

2. TWI Job Methods PPT Training Presentation (PowerPoint format)

3. TWI Job Relations PPT Training Presentation (PowerPoint format)

4. TWI Job Safety PPT Training Presentation (PowerPoint format)

5. TWI Problem Solving PPT Training Presentation (PowerPoint format)

6. Job Instruction Breakdown Sheet (Word format)

7. Job Instruction Training Timetable (Word format)

8. Job Instruction Training Matrix (Excel format)

9. Job Methods Breakdown Sheet (simple) (Word format)

10. Job Methods Breakdown Sheet (8.5x11) (Word format)

11. Job Methods Breakdown Sheet (8.5x14) (Word format)

12. Job Methods Improvement Proposal Sheet (Word format)

13. Job Relations Situation Analysis Sheet (Word format)

14. Job Relations Case Study (Word format)

15. Job Safety Breakdown Sheet (Word format)

16. Problem Solving Problem Analysis Sheet (Word format)

17. Problem Solving Causation Analysis Sheet (Word format)

18. JI Pocket Card (PowerPoint format)

19. JM Pocket Card (PowerPoint format)

20. JR Pocket Card (PowerPoint format)

21. JS Pocket Card (PowerPoint format)

22. TWI E-Pocket Cards - JI, JM, JR & JS (PowerPoint format)

23. Five Needs Model Poster (PDF format, in color and monochrome, printable in A3 size)

24. JI Poster (PDF format, in color and monochrome, printable in A3 size)

25. JM Poster (PDF format, in color and monochrome, printable in A3 size)

26. JR Poster (PDF format, in color and monochrome, printable in A3 size)

27. JS Poster (PDF format, in color and monochrome, printable in A3 size)

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