Putting Job Methods in Perspective

2013 TWI Summit – Savannah, GA

Don’t worry about sitting through a history lesson.

The history based slides will be available for furtherdiscussion in the evening Geek Session.

Objective is to provide insights on the interconnectedrelationships of the TWI programs.

Neuroscience can offer insights on how Toyota’s useof TWI was different, reflected in behaviors developed.

Some sample slides…not all of them…

In this session you will learn…

• Some of the sources for the development Job Methods

• Modifications to Job Methods program– A3 job breakdown form

– Flow example replacing ‘radio shield’

• Toyota’s use of Job Methods– Shingo’s “P Course”

– Kaizen

• Using JI and JR skills to enhance Job Methods– Connecting skills learned to JM use

• Adapting TWI to today’s needs– Applying neuroscience for better results

US Training Numbers

Ratios of training byprogram are similar

in other nations

Original Purpose of Programs

Individual purpose,designed to solvespecific problems

Firefighting approach

Common Format

4–Step Method

Integration came later

Realization of their integration came after the fact

Insights began in the first year as programs were improved.

Job Methods objectives

• The objective was to build a basic IndustrialEngineering program without the engineeringnomenclature.

– Development started in NJ

– Primary developer Clifford Cox

• Had attended one of Mogensen’s weekend programs

• Example had to be simple, using available materials– “Radio Shield” example was invented

• Leaders were to learn how to simplify jobs

JM’s Weakness

Example contrived

Lack of workspace on forms

Acting instead of training

Original example

Radio

Shield

project

TWIF replacement example

More

complex,

multiple

processes

NZ variant

One of

several

variants

found

British variant

Work

Simplification

modification