1
Lengthy onboarding
New employees take too long to reach the expected level of safety, quality and pace.
Technical partnerand workshop host
Open TWI workshop at the factory
Effective on-the-job training with TWI Job Instruction and DOJO
The open TWI workshop at Ikano Industry gives you two days working with real production processes. Learn to turn work standards into effective instruction, faster onboarding and consistent quality.
When28–29 October 20262 days · 14 hours of practice
WhereIkano IndustryRogoźno
GroupMax. 20 participantssmall-group workshop activities
PricePLN 2490 netper person · 2 days
Workshop language: Polish. This page provides the full programme in English. Contact Monika Zaremba to confirm a place or discuss delivery in English; an English-language date has not been announced.
OPEN WORKSHOP
Work with a real process, in a working factory.Three shop-floor sessions, instructions developed at the workstation and feedback from practitioners.
up to 50%shorter employee onboarding time
20–25%fewer errors caused by ineffective instruction
30% → 14%reduction in first-month employee turnover in one implementation
Examples of results from selected LeanTrix TWI implementations. Outcomes depend on the starting point, scale and consistency of implementation.
Ikano Industry — explore the factory and meet the people behind it. Watch the video on YouTube
The factory as a training room
Experience an open TWI workshop on a real process
Ikano Industry in Rogoźno manufactures mattresses for IKEA. Its processes include PU foam, nonwovens, cutting, sewing covers, assembly, warehousing and shipping — providing a broad setting for work on standardisation and instruction.
Three shop-floor sessions and analysis of real workstations.
Work with manual, automated and multi-variant processes.
Share experience with Ikano Industry and LeanTrix practitioners.
Develop instructions you can take back to your own plant.
The problem we address
You have a standard, but everyone trains differently?
An instruction sheet alone does not build competence. You need a consistent way to prepare the job, transfer knowledge and confirm that an employee can work independently.
2
Knowledge held by the expert
Key points for doing the job are not documented, and the departure of an experienced employee creates operational risk.
3
Different approaches to training
Each instructor teaches the job differently, so the standard quickly becomes diluted.
4
Training disconnected from the process
The presentation is sound, but the employee cannot perform the task independently at the workstation.
TWI connects the work standard with the instructor’s competence.
Explore the approachDOJO provides a safe environment in which that competence can be deliberately developed and reinforced.
From standard to independence
Five elements of effective on-the-job training
Observe the process
Identify the task, risks, expected outcome and working conditions.
Break down the job
Describe the important steps, key points and reasons for the key points.
Teach in 4 steps
Prepare the worker, present the operation, try out performance and follow up.
Confirm competence
Use the skills matrix to show readiness and further development needs.
Build a DOJO
Design a practice area and exercise system matched to the real risks in the process.
What you will learn during the workshop
Tools you can connect directly to your own practice
A
TWI Job Breakdown Sheet
Create a TWI Job Breakdown Sheet: important steps, key points and reasons for the key points. During the workshop, you will practise digitising instructions in eTWI and using AI in KaizenUp to create and improve them.
B
The TWI Job Instruction 4-step method
Practise complete job instruction, learner observation and feedback, without shortcuts or instructors reverting to their own way of demonstrating the job.
C
Skills matrix
Connect training to process needs, the level of independent working and a plan for developing multi-skilling.
D
DOJO
Learn how to create a practice environment that develops safety, quality and essential skills.
E
Challenging processes
See how to apply TWI to automation, TPM, variant changes and long-cycle tasks.
F
Implementation plan
Leave with a Start–Stop–Continue plan to turn the workshop into action within your organisation.
Workshop programme
Two days. Three shop-floor sessions. One consistent method.
The open TWI workshop combines short learning modules with demonstrations, instruction practice and workstation activities at Ikano Industry.
From standard to instruction
09:00–10:30
Introduction, health and safety, and foundations
Workshop arrangements and the role of instructions and standardisation in a stable process.
10:45–12:15
How adults learn a job
Common knowledge-transfer mistakes and a practical demonstration of TWI Job Instruction.
12:30–13:30
TWI Job Breakdown Sheet and digitisation in eTWI
Important steps, key points, reasons for the key points and photos supporting the standard, plus an exercise using AI in KaizenUp.
13:30–14:00
Lunch break
14:00–16:30
Process #1 in the factory
Short factory tour, job selection, group preparation of instructions and review at the workstation.
From instruction to a system
08:00–09:00
Improving the instructions
Review of the first day’s work and TWI in complex and non-standard processes.
09:00–10:30
Process #2: two instruction sessions
Complete delivery of the 4-step method on real operations, with feedback.
11:00–12:15
Skills matrix and DOJO
Designing employee development and a case study of a practice environment.
12:15–13:00
Lunch break
13:00–15:15
Process #3 and action plan
Sharing experience, a factory tour and a Start–Stop–Continue plan for your own organisation.
The order of modules may change slightly to accommodate safe working conditions in the factory, without reducing the programme’s substantive scope.
The programme in one file
Open TWI workshop programme
Explore the day-by-day programme or download the PDF to keep or share with your team. The original PDF is in Polish; the full English programme is available on this page.
8 pages · PDF · 1.3 MB · in Polish
The complete workshop scope
The programme includes
objectives, benefits and participant outcomes,
the step-by-step schedule for both days,
three sessions with real Ikano processes,
the optional TWI Instructor certification pathway,
the trainer’s profile and organisational information.
Who it is for
For people responsible for teams, standards or process performance
No prior knowledge of the method is required. The open TWI workshop takes you from the foundations to independently preparing and delivering job instruction.
PRODUCTIONTeam leaders and production managers
DEVELOPMENTInternal trainers and instructors
PROCESSProcess, quality and CI engineers
PEOPLEHR, L&D and onboarding professionals
MAINTENANCEMaintenance and technical team leaders
OPERATIONSManagers building a competence development system
After the workshop, you can…
prepare a Job Breakdown Sheet and identify the key points for performing the task.
After the workshop, you can…
deliver instruction using the four-step method and give feedback.
After the workshop, you can…
assess where TWI and DOJO will have the greatest impact in your process.
After the workshop, you can…
connect training, the skills matrix and an implementation plan into one system.
Optional pathway after the workshop
TWI Job Instruction Instructor Certification — Level II
If you want to confirm your ability to apply the method in your own working environment, you can continue learning after the workshop.
+ PLN 1290 net / person
Explore TWI Instructor Certification →1
E-learning and preparation
Access the materials and prepare two instructions for your own operations.
2
1:1 coaching
Review your Job Breakdown Sheets and practise instruction with feedback.
3
Workplace certification
Verification of complete instruction at a real workstation.
4
Small-scale implementation
Apply the method to two operations and prepare the next development step.
Ikano Industry · Rogoźno
The workshop takes place at an operating manufacturing plant.
Technical partner
Process, people and standards in one place
Ikano Industry opens its plant to participants so that TWI knowledge translates into practice. Every module returns to the question: how can this method be applied to real work?
Direct contact with a real production environment.
Safely organised shop-floor sessions.
A maximum of 20 participants.
Your trainer
Kamil Müller
A LeanTrix expert specialising in standardised work, onboarding, digitalisation and leadership development. He leads TWI implementations and designs on-the-job training systems grounded in real processes.
TWI Job Instruction
DOJO design
Standardised work
Leadership competence development
Participation fee
PLN 2490 net
2 days and 14 hours of workshop activities
exercises on real Ikano processes
training materials
Level I certificate of participation
coffee breaks and lunches
a maximum of 20 participants
Questions? +48 887 120 108 · [email protected]
Your decision and preparation
Reserve your place and bring your own challenge
You will get the most from the workshop if, before arriving, you identify a process where onboarding takes too long, standards are interpreted differently or quality depends on one particular expert.
Accommodationnot included in the price
Level II certificationoptional: PLN 1290 net
Event statusdates confirmed
OrganiserLeanTrix with Ikano Industry
FAQ
Frequently asked questions
If you cannot find an answer, please contact Monika Zaremba.
Do I need to know TWI before the workshop?
No. The programme starts with the foundations and guides you step by step towards preparing a Job Breakdown Sheet and delivering instruction using the four-step method.
Will we really work on the shop floor?
Yes. The programme includes three planned shop-floor sessions. Activities will always follow health and safety rules and reflect current working conditions at the Ikano Industry plant.
What does the PLN 2490 net fee include?
Two workshop days, materials, exercises in the plant, a Level I certificate of participation, coffee breaks and lunches. Accommodation and travel are not included.
What does the optional certification involve?
After the workshop, you prepare your own instructions, receive 1:1 coaching, practise the method and demonstrate your skills during certification in a real workplace. The Level II pathway costs PLN 1290 net.
Can I register several people from one company?
Yes, subject to available places. The group is limited to 20 people so that every participant can practise actively and receive feedback.
How should I prepare for entering the factory?
Before the event, you will receive detailed organisational information, health and safety rules and requirements for entering the plant.
Original implementation diagram in Polish. The English case study explains the full six-stage model and its June 2026 status.
Ikano Industry case study
See how Ikano connects TWI with production goals
The situation presented in June 2026: stage 4 of 6 — preparing trainers, certification and developing instructions.
Explore the journey from an unsuccessful first initiative to a system based on process needs, trainer preparation and a measurable approach to competence development.
Read the Ikano TWI implementation case study →Client references
Practice endorsed by production teams
The workshops were 100% practical, built around numerous examples and exercises.
Joanna Szmycińska-SłowikHR Business Partner · Geberit Produkcja
Every training course delivered by LeanTrix was conducted thoroughly and adapted to our organisation’s needs.
Karolina GrześkiewiczHR Specialist · Viessmann
The company showed an open approach and a willingness to develop individual solutions that strengthened the effectiveness of our activities.
Paweł KonsewiczProduction Manager · JOST Polska
Build a system in which good work can be taught well
28–29 October 2026 · Ikano Industry in Rogoźno · a maximum of 20 places