Wienerberger: Implementing TPM through TWI
Wienerberger – Implementing TPM through TWI. This article summarizes…
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Lean and TWI case studies: 26 TPM implementations
CASE STUDIES
Recaro: Work Standardization and Efficiency
Recaro Work standardization is not documentation – it is…
eOBUWIE.pl: Implementation of the TWI in e-commerce logistics
TWI in e-commerce logistics. The TWI program in logistics is gaining…
Danone: TWI Implementation at Food Industry
TWI in Danone – case study. Imagine a windmill, old and…
Nidec Automotive: How to Engage Operators into TPM Activities
Nidec Automotive – Case Study. This material is based…
Tarczynski: TWI in Food Industry
TWI in Food Industry – case study from Tarczynski company.…
Rolls-Royce Poland: A Case Study of Lean Management, TWI, and HR
The Rolls-Royce Poland factory is located in Gniew. As part of…
Cooper Standard Automotive: Lean and TWI in Automotive
TWI in Cooper Standard is known as a BTO. Cooper Standard is…
26 Lean and TWI case studies from 25 companies. Explore measurable TPM implementations across automotive, FMCG, manufacturing, logistics, healthcare and services.
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VELUX: TWI Reactivation
Onboarding reduced from 30 to 10 days, quality errors down 17%, and ergonomics up by 3 points. VELUX shows how to reactivate TWI successfully.
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Atlas Ward: Lean Gamification in Process Learning
100% of employees trained, process awareness up 30.86%, and an average score of 4.97/5. Atlas Ward used Lean Gamification to teach processes.
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Bosch: Production Digitalization Supporting Continuous Improvement
Three applications: paperless production, digital problem solving, and TPM reviews. Bosch made technology serve the process and its purpose.
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Lear Corporation: Implementing Lean in a Strong Hierarchy
Five Lean mechanisms and four practices that reduce micromanagement. Lear shows how to move from control toward developing people.
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LEK-AM: Lean Transformation from Processes to Digitalization
Transformation launched in 2024: 5S, SMED, TPM, Kaizen, and reliable data before digitalization. LEK-AM is building a sustainable Lean system.
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Impel: Small-Scale Digitalization as a Path to Major Change
54 tools implemented and 70 ideas stopped within 12 months. Impel shows how to manage a portfolio of small-scale digitalization initiatives.
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Auchan: Reporting Automation and Faster Decisions
The contract cycle was reduced from about a month to one week, while access administration fell to two hours per month.
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Czanieckie Makarony: Improving OEE
Approximately 10,000 tonnes of annual production and MES data used for OEE analysis. Czanieckie Makarony shows a data-driven improvement path.
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LOT: Process Management Focused on Improvement
One shared goal, clear roles, retrospectives, and pilots. LOT shows process management focused on continuous improvement.
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DeLaval: Transforming Manual Processes into Automated Ones
VSM, Yamazumi, PFMEA, and mock-ups before automation. DeLaval transformed a manual process without overlooking ergonomics and quality.
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ZF Group: Implementing a Dojo in the Automotive Industry
99.33% satisfaction, 87% knowledge-test score, 2.3% errors, and 4% micro-stoppages. This is how ZF measures its Dojo.
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RECARO: Increasing Resource Utilization by Eliminating Waste
The relative capacity index increased from 1× to 4× without building a new production hall. RECARO released resources by eliminating MUDA.
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Asahi Group: Implementing 5S and TPM in Brewing
5S combined with autonomous maintenance. Asahi shows how operators and maintenance teams jointly build a TPM standard.
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Affidea: Standardizing Magnetic Resonance Imaging
Three earlier attempts did not create a lasting effect. Affidea rolled out MRI standards in batches and achieved a high adoption level.
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Ikano Industry: TWI Implementation
6 implementation stages, 4 instruction steps, and 3 business KPIs. Ikano Industry shows how to reactivate TWI without inventing unconfirmed results.
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Penta Hospitals: Lean Implementation in Healthcare
Admission time reduced from 181 to 52 minutes, inventory down by approximately 38%, and the team regained 146 hours annually.
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SP ZOZ Kościan: Lean in a Hospital
8.5% of scheduled procedures were postponed in a sample of 398 cases. SP ZOZ Kościan presents the diagnosis and the designed future-state standard.
Full case study in PolishRead the case studyWienerberger: Implementing TPM through TWI
50 TWI instructors, 20 leaders, and 4 regional roles. Wienerberger uses TWI to scale TPM autonomous maintenance.
Read the case studyeOBUWIE.pl: TWI in E-commerce Logistics
The 4 steps of TWI Job Instruction structured training in fast-growing e-commerce logistics and supported internal instructor development.
Read the case studyRECARO: Work Standardization and Efficiency
Onboarding time reduced by 50% and 20% fewer errors causing scrap. Work standardization and TWI at RECARO.
Read the case studyDanone: TWI Implementation in the Food Industry
Onboarding time reduced by 37% in warehousing and 50% in production, with greater employee skills flexibility.
Read the case studyCooper Standard: Lean and TWI in Automotive
Productivity increased by 17.55% and defects fell by 35.83%. Cooper Standard combined TWI, work standardization, and continuous improvement.
Read the case studyTarczyński: TWI in the Food Industry
Learning time reduced by 25–30%. Tarczyński shows how TWI Job Instruction standardizes training in food production.
Read the case studyAutoliv: TWI in Automotive
20% of production lines covered and 4 certified TWI instructors. Autoliv shows how to scale work standardization in automotive.
Read the case studyNidec: TPM in Automotive
The impact of machine losses fell from 3.8% to 1.31%. Nidec developed TPM, operator ownership, and maintenance capabilities.
Read the case studyRolls-Royce: Lean HR in Marine Engineering
Two perspectives: Lean HR and TWI. Rolls-Royce shows how work standards support skills development in advanced engineering.
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