Our friend Jeff Kidner asks another great question. Has this ever happened in your company?
We are trying to use JI at the moment on a whole new production line involving several new pieces of equipment. The project timeline only permits a few days of work-sharing the equipment with the equipment installers. In effect the JI instructors have had to write the breakdowns based on the knowledge gained from training off site with the manufacturers and what little time they have had on the machines themselves on site-albeit not fully functional.
I was wondering if you have experience of using JI in a similar circumstance on new equipment, where the JI instructors knowledge may not be as extensive as where they are writing breakdowns for established operations and how best to manage this?
TWI Institute Master Trainer Richard Abercrombie offered his insight:
Of course, this is an issue for management of the line organization, not something to be left to the wits of the JI instructors. The plan for making this kind of change in production should include serious consideration of training and resources necessary to be successful from the very beginning.
The Training Timetable is intended to be used whenever there are changes in production so that the training needs are addressed in a planned way. In this case, management of the line organization owns the training timetable as one of the planning tools for implementing new production capacity. The timeline for the project needs to identify the major milestones and the time and resources necessary to achieve them. Training is one of those milestones and preparation of the instructors is a supporting task detail.
Allowing insufficient access to the new equipment for instructors to prepare adequate breakdowns strikes me as a plan for trouble.
But even if time is made available, you’ll learn more and more as the production operation begins. I think key points will be coming up often as the instructors and operators gain experience and you’ll have to modify breakdowns accordingly.