The Annual TWI Summit Geekfest
with Mark Warren

Session Abstract:

FROM MARK WARREN… I’m planning on talking about my current experiment where we did limited classroom training. The training was just an overview to let the people know the tools existed when we had problems to address. We were also telling them the basic ideas of TPS, as found in the 1st chapter of the 1973 manual. Part of my experiment was to replicate some of the same learning that the 1st tier suppliers of Toyota had starting about 1970. Basic lean principles + TWI.

Our focus was on problems solving (eliminating the hidden rework factories), creating flow (balancing the lines), making the jobs easier for the operators, and eliminating unnecessary activities that they considered ‘normal’. While they had a couple of hours exposure on the TWI skills, there was not enough practice and training for them to define what traditional use looked like. This was interesting, because they began to apply the Job Breakdown approach to problems in a way that was quite non-traditional. It started with the request to facilitate doing the JBS on an automatic section of a line… about 10 stations. They first described the step at the station, then the key points that must happen correctly to create a good product. The team used this for trouble shooting when defects were discovered. The Key Points made it easy to locate the source and resolve. Others have created instructions to do changeovers; following the JI format to recognize there is a get ready step and a follow up step (put away and inspect). Another used JI to design production requirements on a special order with a few samples. They had done a similar order like this last year and struggled. The first batch of 10,000 was done in December and took half the labor as it took in 2016.


About the Presenter:

Mark Warren has 30 years of experience working with Tier 1 and 2 suppliers to improve their manufacturing productivity and quality. Prior to establishing an independent consultancy, Tesla2, he spent 12 years at Robert Bosch Corporation in the corporate Quality Assurance and Warranty Department, where his responsibilities entailed extensive cooperative projects at various Bosch, supplier and customer facilities in Latin America, Europe, and Asia.  Mark is probably the foremost expert in the world on the Training Within Industry (TWI) programs.  He has resurrected the original materials from the National Archives posting them on the web for everyone’s benefit and has researched across the globe other countries variations of the original programs.  Currently he coaches individuals and organizations on implementation of the TWI programs both domestically and internationally.  Mark has presented at numerous lean and TWI conferences and is the author or editor of several books and papers on TWI.