TWI Program: Problem Solving (PS) Training

Views:
 
     
 

Presentation Description

Training Within Industry (TWI): The TWI Problem Solving (PS) program trains supervisors in how to solve problems in order to achieve the desired results. Based on the TWI four-step model, the TWI-PS program integrates and elevates the three original TWI skills (JI, JM and JR) into a problem-solving focus. Learning Objectives 1. Solve problems based on the 4-Step Process for Problem Solving 2. Apply the Problem Analysis Sheet and the Causation Analysis Sheet to analyze and identify root causes 3. Apply the JI, JM and JR skills and tools to solve the problem Contents Basic Needs of Supervisors Supervisor’s Responsibilities Introduction to Problem Solving Objective of Problem Solving Results from PS Training Comparison of Toyota & TWI Problem Solving Steps What Is a Problem? 4 Steps for Problem Solving Step 1: Isolate the Problem Problem Analysis Sheet Causation Analysis Sheet Step 2: Prepare for Solution Mechanical & People Problems Step 3: Correct the Problem Step 4: Check and Evaluate Results Summary To download this presentation, visit: http://www.oeconsulting.com.sg

Comments

Presentation Transcript

Slide1:

Training Within Industry Problem Solving (PS)

Learning Objectives:

Learning Objectives Solve problems based on the 4-Step Process for PS Apply the Problem Analysis Sheet and the Causation Analysis Sheet to analyze and identify root causes Apply the JI, JM and JR skills and tools to solve the problem Copyrights of all the images used in this presentation are held by their respective owners.

Outline:

Outline Basic Needs of Supervisors Supervisor’s Responsibilities Introduction to Problem Solving Objective of Problem Solving Results from PS Training Comparison of Toyota & TWI Problem Solving Steps What Is a Problem? 4 Steps for Problem Solving Step 1: Isolate the Problem Problem Analysis Sheet Causation Analysis Sheet Step 2: Prepare for Solution Mechanical & People Problems Step 3: Correct the Problem Step 4: Check and Evaluate Results Summary NOTE: This is a PARTIAL PREVIEW . To download the complete presentation, please visit: http:// www.oeconsulting.com.sg

Program Benefits:

Program Benefits Positively reinforces the role of the supervisor regarding problem solving Gives the supervisor a simple and repeatable method to solve problems based on the TWI model Enables immediate application of the supervisor’s ideas Involves the supervisor with the workforce in collaborative solutions

Basic Needs of Good Supervisors:

Basic Needs of Good Supervisors SKILL Instructing Leading Improving Methods Work Responsibilities KNOWLEDGE Safety

Supervisor’s Responsibilities:

Supervisor’s Responsibilities What supervisors are responsible for: Quality Production Cost How they achieve those responsibilities: Knowledge of work Knowledge of responsibilities Skill in instructing Skill in leading Skill in improving methods Safety component to all the above needs

Introduction to Problem Solving:

Introduction to Problem Solving The Problem Solving program was developed in order to provide management with a process whereby supervisors could acquire skill in solving problems Require supervisors to apply the following skills: Job Instruction (JI) Job Methods (JM) Job Relations (JR)

Introduction to Problem Solving:

Introduction to Problem Solving Constant need to increase profitability and productivity and with less resources Today’s production problems are more complex and require analytical approaches to solve them PS is not a program to make people work harder or faster Purpose of PS program is to give us a systematic approach to problem solving

Objective of Problem Solving (PS):

Objective of Problem Solving (PS) Provide supervisors with a systematic way to solve problems in order to achieve the expected results

Results from PS Training:

Results from PS Training Increased customer satisfaction Increased market share Lower costs Faster delivery time Increased profitability Increased efficiency Improved morale

Comparison of Toyota & TWI Problem Solving Steps:

Comparison of Toyota & TWI Problem Solving Steps Toyota Problem Solving Steps TWI Problem Solving Steps 1. Clarify the problem Isolate the problem State the problem Give proof or evidence Explore the cause Draw conclusions 2. Break down the problem 3. Set targets 4. Conduct root cause analysis 5. Develop countermeasures 2. Prepare for solution Use JM, JI & JR steps 1 and 2 6. See countermeasures through 3. Correct the problem Use JM, JI & JR steps 3 and 4 7. Monitor both results and process 8. Standardize successful processes 4. Check and evaluate results

What Is a Problem?:

What Is a Problem? A supervisor has a problem when the work assigned fails to produce the expected results Standard – what should be happening Current situation – what is actually happening Gap = Problem

The 4-Step Method for PS:

The 4-Step Method for PS Isolate the Problem Prepare for Solution Correct the Problem Check and Evaluate Results

Step 1 — Isolate the Problem:

Step 1 — Isolate the Problem 1. State the problem Pick up current problems Problems up to now New problems breaking out Approaching problems Look for and find problems Anticipate and foresee problems Discussion and review of records Prioritize Importance, necessity, emergency level Step 1: Isolate the Problem

Step 1 — Isolate the Problem:

Step 1 — Isolate the Problem 2. Give proof or evidence of the problem View with an open mind Talk with people, review records Gather facts, circumstances, figures, etc. that directly show the problem From the Mechanical angle: schedules, rework and scrap, equipment breakdown, accidents, etc. From the People angle: productivity, knowledge and skill, safety, interest, job satisfaction, etc. Step 1: Isolate the Problem

Slide16:

Step 1: Isolate the Problem State the Problem Draw Conclusions Explore the Cause Give Proof or Evidence

Chain of Causation vs. 5 Why’s:

Problem Evidence Causes Direct Indirect Core/Root Customers complaining about late deliveries. On-time delivery stands at 87%. Packaging delays creating a bottle-neck of finished product. Delivery of packaging product is frequently delayed from printer. Films from art department are being held up waiting for confirmations. Need corporate approvals for correct usage of all company logo marks. Poor communication between corporate marketing and plants. Chain of Causation vs. 5 Why’s Step 1: Isolate the Problem 1 2 3 4 5

Step 2 — Prepare for Solution:

Step 2 — Prepare for Solution Step 2: Prepare for Solution Problem People Problem Mechanical Problem Don’t care/ Won’t do Don’t know/ Can’t do Knowledge & Skill Development Attitude & Behavior Correction Method Improvement Use JI Use JR Use JM

For Mechanical Problems:

For Mechanical Problems First, analyze the overall job or situation Cast a “wide net” Use Flow Charts and Flow Diagrams to list and map the routing and location of parts, materials, data, etc. Next, analyze the specific job or situation Breakdown the job method by listing all details Question all details to locate problem sources Step 2: Prepare for Solution

For People Problems:

For People Problems Don’t Know Can’t Do Don’t Care Won’t Do Faulty Instruction Wrong Assignment Personality Situation Step 2: Prepare for Solution

Slide21:

Step 3: Correct the Problem Use JM for mechanical problem Use JR for people problem (Don’t care / won’t do) Use JI for people problem (don’t know / can’t do)

Step 4 — Check & Evaluate Results:

Step 4 — Check & Evaluate Results Follow up to see that the change or correction has been made Look at what improvement the records show in quality, quantity, safety and cost Consider the human angle – note changes in attitudes and relationships Inform all concerned of the progress and results of the action or correction Look for ways to prevent problem recurrence Step 4: Check & Evaluate Results

Other Presentations You May Like…:

Other Presentations You May Like… Check out our presentations catalog at http://www.oeconsulting.com.sg/#!training-presentations/ c1les

About Operational Excellence Consulting:

About Operational Excellence Consulting

About Operational Excellence Consulting:

About Operational Excellence Consulting Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. The firm’s mission is to create business value for organizations through innovative operational excellence management training and consulting solutions. OEC takes a unique “beyond the tools” approach to enable clients develop internal capabilities and cultural transformation to achieve sustainable world-class excellence and competitive advantage. For more information, please visit www.oeconsulting.com.sg

END OF PREVIEW:

www.oeconsulting.com.sg END OF PREVIEW To download this presentation, please visit us at:

authorStream Live Help