TWI & Kata: A Problem Solving Approach
Presented By:
Patrick Graupp & Scott Curtis
Session Abstract:
Developed as a war program in the 1940’s TWI built capability in organizations by providing frontline management with the basic skills of Job Instruction (JI), Job Relations (JR) and Job Methods Improvement (JM) to successfully ramp up and sustain the production of war materiel for the allied armies to win WWII. Implemented throughout Japan after the war, and most famously at Toyota, TWI provides companies struggling to maximize the benefits from Lean a proven way to focus on the people side of Lean and build a solid foundation through effective front line leadership and coaching.
More recently, TWI practitioners have recognized basic similarities between the practice of TWI and Toyota Kata. The emphasis on practicing routines in order to master them (make them daily habits) flows through both disciplines. What is more, the TWI skills complement and enhance the advancement of the Improvement Kata and align perfectly with the Coaching Kata.
In this workshop the group will work on solving an actual problem following Improvement Kata practice in order to learn and use the TWI skills. We will review the TWI methods and then guide hands-on practice to show how the methods lead to problem solving directed by the Coaching Kata.
Finally, we will review how TWI is being integrated with Kata practice in a worldwide TWI roll-out across three continents currently being done by Magna Powertrain.
Specific Learning Objectives:
In this session you will learn:
- The 4-step method of the TWI programs
- How JI, JR and JM build effective front line leaders and coaches
- How TWI integrates with Toyota Kata practice and is the foundation of Kaizen and CI methodologies
- How TWI Problem Solving enables supervisors to coach team members to solve problems on the shop floor
Presenter Bio:
Patrick Graupp, Senior TWI 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 from his mentor Kazuhiko Shibuya. Mr. Shibuya was trained by Kenji Ogawa who was trained by the four TWI Inc. trainers sent from the US to help Japan rebuild industry in 1951. Patrick earned an MBA from Boston University while heading Sanyo’s global training effort. He was later promoted to the head of Human Resources for SANYO North America Corp. in San Diego, CA where he settled.
Patrick helped establish the TWI Institute, which has since trained a rapidly expanding global network of close to 1000 certified trainers who are now delivering TWI training in the manufacturing, health care, construction, energy, and service industries in the US and around the globe. He has authored numerous books on TWI including The TWI Workbook: Essential Skills for Supervisors, Implementing TWI: Creating and Managing a Skills-Based Culture, Getting to Standard Work in Health Care: Using TWI to Create a Foundation for Quality Care and Building a Global Learning Organization: Using TWI to Succeed with Strategic Workforce Expansion in the LEGO Group. The TWI Workbook and the Building a Global Learning Organization are Shingo Research and Professional Publication Prize Recipients.
Scott Curtis – Scott brought 25 years of manufacturing experience and leadership and a deep working knowledge of TWI programs when he joined the TWI Institute in 2012. Since then, he has been working on growing the Institute into a Global leader in TWI with partner locations throughout Europe, Asia and the America’s.
Scott began his career with Mobil Chemical and held several engineering and management positions including Plant Superintendent and Plant Manager in his 13 year career with Mobil/Pactiv. Scott spent 5 year at Huhtamaki Consumer Packaging as Op’s Manager and 7 years at Albany International as Plant Manager.
Scott has training in Six Sigma from the University Of Tennessee Knoxville, and earned a bachelor’s from the Rochester Institute of Technology and an MBA from the University of Phoenix.