TWI Job Instruction - Kaizen

A TWI Job Instruction Kaizen Event was used toKaizen Event in just 3 days... 24 hours in total!
dramatically reduce paperwork and simplify the trainingThere were 10 discrete processes used in the
process in a medical device manufacturing company inproduction of the chemicals and the resultant batch of
Atlanta.formulation. Every process has a quite lengthy SOP.
This industry, especially, is characterized by largeProcess associates were trained using the SOPs.
amounts of data entry and records management toMistakes were being made in the 100's of data entries
document virtually evey detail in the production andrequired by the standard documentation. NCRs
inspection process. Various functions such as(Non-Conformance Reports) were written and the
Document Control, Configuration Management,process operator then had to go through even more
Records Management, etc are created to keeptraining to try to prevent the problem from happening
control of this documentation and the informationagain. No luck!
contained therein. Often, product cannot be releasedTWI Job Instruction training enabled the supervisors to
for sale without the proper documentation, so recordscreate 40 Job Instruction Breakdowns, then create a
management is a control function.MFWTT (Multi-Function Worker Training Timetable) in
To complicate things in this particular instance, theorder to greatly simplify (and mistake-proof) the job
company also uses SOPs (Standard Operatingskills training in this area. The supervisors learned the 4
Procedures) as work instructions that are written intosteps for proper job instruction, then developed an
the documentation records. As an example, if animplementation plan to train all of their people on 4
operator needs to turn on a swith to start a machine,shifts.
this action itself was documented on the formalFinally, the SOP detail instructions were deleted from
records. Sometimes these actions even required athe batch record (formal documentation) so the
"witness" to verify the action was performed. Theconcentration could now be on test results and
result: for each batch of chemical formulationcompliance verification.
produced, the company averaged 400 pages ofResults: approximately 400 pages of documentation
documentation and 7200 entries. Many errors werewas reduced to less than 10! And 7200 specific data
being made and even more control was applied. Theentries were reduced to less than 50! Batch record
situation was getting worse!accuracy increased to 100%. Batch defects went to 0!
TWI Job Instruction was selected as the means toCompliance runs at 100%! Quality of worklife for
both a) simplify the training and b) reduce the errorseveryone is much greater! Everyone wins!
being made in the documentation. This was done as a