Implementing the TWI program is quite a challenge for both manufacturing and service companies. The TWI (Training Within Industry) program is a method developed during World War II to help supervisors and production leaders develop key on-the-job skills. Although much has changed since then, its effectiveness in training and process improvement remains invaluable. To fully unlock the potential of the TWI program, it must be implemented comprehensively, not limited to simply creating work instructions. It’s important to remember that this program encompasses far more than just documenting procedures.
TWI Implementation and the Effectiveness of Work Instructions
Too often, work instructions are seen as the main or even the only element of the TWI program. This misconception leads to the belief that merely preparing documentation is enough to effectively train employees and ensure process stability.
In reality, a work instruction is only a tool—not an end in itself. Its true value emerges only when it becomes part of a well-structured teaching system based on the TWI Job Instruction method—built on observation, practical demonstration, and the conscious communication of key points.
Just as with the 5S method, which is often wrongly equated with “keeping things tidy,” the real essence of TWI lies in integrating its philosophy into daily practice rather than treating it as a one-time project.
5S is not about cleaning; it’s about creating a work environment that promotes efficiency, safety, and engagement. Similarly, TWI is not about generating paperwork but about building the capabilities of leaders and trainers who can effectively develop employees’ skills and sustain work standards over time.
The true success of the TWI program begins when its principles—teaching, improvement, and relationships—become a natural part of daily management. Only then does documentation truly matter, as it reflects a living standard of work rather than a static collection of procedures.
How to Implement the TWI Program Effectively
If the focus is solely on documentation, without actively using it in training processes, the outcomes will be disappointing. Employees may fail to see the importance of keeping instructions up to date, leading to frustration and disengagement. As a result, the TWI program loses value and fails to deliver the expected results.
Implementing the TWI Program – A Holistic Approach
The TWI program is much more than just creating work instructions. It consists of several key components that together form a strong foundation for effective training and process management. The three core areas of TWI are:
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TWI Job Instruction – Effective knowledge transfer and process documentation.
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TWI Job Methods – Process improvement through waste elimination.
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TWI Job Relations – Building team engagement and resolving conflicts.
Implementing all of these elements is essential to fully benefit from the TWI program.
Expanding the TWI Program with New Elements
Over the years, the TWI program has been expanded with two additional modules, significantly increasing its effectiveness and scope:
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TWI Job Safety – Creating and maintaining a safe working environment.
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TWI Problem Solving – Identifying and eliminating problems at their source.
These additions have made TWI a comprehensive tool that helps production leaders not only train new employees but also improve production processes and enhance workplace safety.
TWI Implementation – Key Takeaways
For the TWI program to deliver its full benefits, implementation must be holistic and systemic. Focusing on just one element—such as creating work instructions—will not produce lasting results. Only a comprehensive approach that develops all key leadership skills—Job Instruction, Job Methods, Job Relations, and Job Safety—enables organizations to fully harness the power of the TWI program.
Equally important is involving the entire team when implementing TWI. This is not a one-off training initiative but a long-term process of developing leadership skills, fostering a learning culture, and creating an environment where every employee understands their role in maintaining safety, quality, and process efficiency.
TWI in the Age of Artificial Intelligence
Today, the TWI program is entering a new era through the use of artificial intelligence. Tools like KaizenUp AI support leaders in process analysis, risk identification, and generating improvement ideas aligned with TWI principles. AI also assists in creating work instructions, safety cards, and method improvement proposals, which can then be verified and implemented by the team. This synergy between human experience and technology enables organizations to develop faster, safer, and more effectively.
Conclusion
TWI is not just a tool for documenting procedures—it’s a strategic approach to organizational development that connects people, processes, and modern technology. Through integration with AI solutions like KaizenUp, the TWI program becomes an even more powerful system for building capabilities, optimizing processes, and creating teams that are engaged, aware, and ready to solve problems in the spirit of continuous improvement.
Training Within Industry and Lean Management Practitioner.
He is a lecturer at the WSB University in Wrocław. He is the author and co-author of several pieces of literature on the TWI program.
He is a managing partner in the LeanTrix company and a master Trainer for Europe. Additionally, he is involved in projects such as eTWI System and Lean Community
He has run projects for: Lotte Wedel, Danone, Kompania Piwowarska, eobuwie.pl, Arvato, Whirlpool, B / S / H, Geberit, RECARO, Tenneco, Sumitomo Electric, Stadler, Vesuvius Poland
Maciej Antosik – management student at Wrocław University of Science and Technology. I support the Leantrix team in carrying out projects. Among other things, I was responsible for implementing the conference application during the Lean TWI Summit. Currently, I am responsible for marketing and also collaborate on the creation of Kaizen UP and Wiktor Wołoszczuk’s podcast.
Outside of my studies and work, I am developing as a personal trainer and train professionally in powerlifting. Sports teach me discipline and consistency, which I also apply in my professional life. What brings me the greatest satisfaction is personal growth and achieving long-term goals that require courage and pushing beyond my own limits.
In my free time, I am passionate about cooking, traveling, and music – these are spaces for me to act creatively and discover new inspirations. I consider myself ambitious and open-minded, always ready for the next challenge.
