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OVERVIEW The four training programs developed by TWI were developed in an emergency situation by experts on loan from private industry. Because of the intensity of the situation, a large number of experimental methods were tried and discarded. This resulted in a distilled, concentrated set of programs. The TWI trainers had to be invited to a factory in order to present their material. In order to market the service, they developed the Five Needs of the Supervisor: every supervisor needs to have Knowledge of the Work, Knowledge of Responsibility, Skill in Instructing, Skill in Improving Methods, and Skill in Leading. Each program was based on Charles Allen's 4-point method of Preparation, Presentation, Application, and Testing. The four programs were:
There was also a short-lived course that taught union personnel to work effectively with management. Relationship to Lean Although the TWI program was abandoned at the end of the war, the instruction methods were introduced to the war-torn nations of Europe and Asia. It was especially well-received in Japan, where TWI formed the basis of the Kaizen culture in industry. ''Kaizen'', known by such names as ''Quality Circles'' in the West, was successfully harnessed by Toyota Motor Corporation in conjunction with the Lean or Just In Time principles of Taiichi Ohno . In fact, in the Introduction to Dinero (2005), John Shook relates a story in which a Toyota trainer brought out an old copy of a TWI service manual to prove to him that American workers at NUMMI could be taught using the "Japanese" methods used at Toyota. Thus, TWI was the forerunner of what is today regarded as a Japanese creation. TWI had a direct impact on the development and use of kaizen and Standard Work at Toyota. These fundamental elements are embedded within the functional system at Toyota and Job Instruction is taught and used within Toyota today. The kaizen methodology is a direct descendant of Job Methods, and most likely Job Relations had an impact on the development and function of the Team and Group Leader structure in Toyota. Many of the points above should look familiar to students of W. Edwards Deming . The PDCA style of the training programs, the JI litany about failure being on the shoulders of the instructor, and even the JI and JM methods themselves. Deming lectures frequently included statements similar to the JR slogan, "People Must Be Treated As Individuals." Why it disappeared from the United States One theory for the disappearance of TWI within the U.S. after the war is the simple fact that North American industry faced little serious competition in 1945. With no competition to an efficient industry, few saw the need to continue to improve. At the same time, foreign industries had been decimated. The defeated countries needed to establish new industry but to reject the old culture. For that purpose, TWI trainers were brought to Europe by the occupying forces there, and to Japan by Macarthur during the occupation. SEE ALSO REFERENCES
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