JI CardHack - Arrange the Work Area

Last CardHack release for the Job Instruction Get Ready points. This one, like the last, has strong tie-in to 5S skills.

Head over to TWI Service to read more...

Coming soon: Now that you have prepared, its time to instruct - JI 4 Step CardHacks.

TWI CardHacks - "Have Everything Ready"

"Have Everything Ready" Doesn't really have that flashy Lean sound does it? It doesn't have the name recognition of problem killers like 5S, PokeYoke, Kanban, etc. Yet, this Get Ready point may be the most overlooked Lean key point of them all. One of the reasons for this is that we often take for granted that Everything is um, already, Ready.

On one of my first practice Job Breakdown Sheets, I went out to the floor in a web coating operation. I was interested in a breaking down a changeover job that involved some calendaring rolls. The rolls, quite heavy, were supported by a bearing block on each end, about seventy five lbs. each. When I watched the mechanic pull the bearing off the roll, he used a precarious trick to move the 75lb. block from the roll end, hanging in the air, and over to the workbench about six feet away. His trick was to slide the block and rest it on his thigh, and then shuffle over to the work bench while supporting the block with this hands and thigh.

Perhaps you can imagine what I was thinking: "I won't write down this key point!" 

Number one, what I observed was clearly unsafe - potential problems were back injuries, broken toes, broken feet, pulled muscles, lacerations or crushed digits if he smashed his finger between the block and the work bench.

Also, if he managed to do the job unscathed, which he often did, what if he dropped the block on the ground? Damage to the bearing and the floor was at risk, causing unneeded expense. In addition, without knowing if spare bearings were available, the damage could result in unplanned downtime and missed promise dates or shutdowns of subsequent production lines.

You, see the workplace was NOT ready. This is one example, of tens of millions, that plague our workplaces. When you right a job breakdown sheet, don't just write down what you see. This is your opportunity to question what it is you see. This is one of the hidden benefits of using a questioning method as we are taught when pulling keypoints out of the job. It leads us to Learn to See problems in the workplace.

In this way, we are tuning our eyes to see problems in the workplace.

After talking about the problem in more detail, I learned that not only did the nightmare potential problems flashing through my mind were valid, some of them had already happened. It was time to make an improvement and stop the chain of accidents and problems cold in their tracks. We talked little more and we found an extra die table that needed repair, but would do the trick. After we fixed the control valve on it, he could raise the table to the end of the roll, safely slide the block onto the table, wheel the table over to the workbench and then safely slide the block onto the bench for maintenance.

We felt a lot better about writing down "Use die table" in the keypoints. Better yet, the mechanics quickly rattled off the reasons why with total buy-in.

Check out the TWI CardHacks for "Have Everything Ready". By doing so, you can set the example of how work should be done safely, correctly, quickly and conscientiously in the workplace.

Job Breakdown Sheets CardHacks - NZ Coaching Guide

More TWI CardHacks...the link takes you to the NZ Coaching Guide for Job Breakdown Sheets. The purpose of this Coaching Guide is to coach a supervisor in preparing a job breakdown sheet and in using the JBS. The guide is useful during the Job Instruction program deployment or as a follow-up guide.

One of the things that I'm not known for in my blog post is brevity. I like to think that is because I'm smart, but I'm pretty sure it has more to do with me learning how to write.

A curious thing about this Coaching Guide, the word "brevity" is used twice. Brevity means: "concise and exact use of words in writing or speech." I find it difficult to write about lean and TWI because there is so much content that spans management, technology, culture, etc. that I don't know how one can write about such a complicated topic with brevity.

Interestingly enough, the NZ coaching guides, appreciation programs and materials are several hundred pages in content - that is a lot to say about 4 step programs!

But what the TWI skill programs really address is human behavior, not 4 step cards. The cards are simply reminders of ways we can behave to get good results.

Coaching Guide #3

TWI CardHacks - Break down the Job

This week we dig into the next Get Ready point: Break Down the Job. Writing a job breakdown sheet (JBS) may seem simple and it is, after a few tries you get  better with pratice. Last week we posted CardHacks for creating timetables. Timetables, when done correctly, list the Job Breakdown Sheets along the top of the form. Once you see the workflow on the timetable it is time to get to work.

A few tips:

Stop thinking admin. Don't go into this thinking that the purpose is to replace your work instruction documents. Writing a document, or replacing one, is not the goal of the organization. The end result is that you dilute the effectiveness and purpose of Job Breakdown Sheets,

Don't write your JBS from behind a desk, go the genba with the person that knows the job better than anybody else. Better yet, write it with a team and compare notes,

Keep it simple. Important steps are best when they are verbs and nouns, or action+object. Don't get wordy, you already have work instructions.

Be open and ready to deal with people. If you have strong interpersonal skills, perhaps you are o.k. If not, it might help to familiarize yourself with the Job Relations skill. When you write Job Breakdown Sheets, you are likely going to find safety and quality problems that involve people. Writing a JBS, a ten minute step, is a small discovery phase in your lifetime lean journey. Discovery leads to commitment to improve. Be ready to take action!

Later this week, we will post some additional materials that support this important skill.

JI Timetable CardHacks - Form Uploads

Just uploaded three file formats of the Job Instruction timetable: MSWord, MSExcel and Google Sheet formats.

One more bonus: Timetable Coaching Guide for Supervisors. This was developed for staff people to coach trainers through development of timetables. Before you jump into Job Breakdown Sheets, make sure you plan out your approach with a timetable first!

http://twiservice.com/JI_Timetable_Cardhack.html

TWI CardHacks - Job Instruction Get Ready Points - Timetables

The link takes you to a new user generated content section on TWI Service.com. I'm very excited and thankful to have TWI experts from all parts of the world contributing to the ongoing development of the program. Contributions have come through the yahoo and linkedin groups and will be posted in these CardHacks, sort of like LifeHacks for TWI and Lean. This week, we start with a CardHack on the Job Instruction skills around Training Preparation and some insight behind the importance and key points in building Timetables.