Why do you need this service?
TWI Job Quality Training builds quality directly into the process. Leaders and operators learn to translate customer requirements into specific behaviours at the workstation so that defects are detected and stopped where they arise.
Quality at source and self-inspection
Operators should know what is critical to quality, how to recognise correct work and why the standard must be followed. Quality key points, OK/NOK criteria, product reference samples, a catalogue of known defects and a clear standard response support this.
Who is it for, and what can it achieve?
The training is intended for production leaders, TWI instructors, internal trainers, and quality and process engineers. The organisation can reduce defects and customer complaints, improve FPY, make self-inspection more effective and stop more problems at source.
The method complements Training Within Industry and TWI Job Instruction. A detailed description is available on the TWI Job Quality page.
What is our role?
- We diagnose key operations and quality key points.
- We teach the 4 steps of TWI Job Quality using a real process.
- We develop OK/NOK criteria, reference samples, a defect catalogue and a standard response.
- We run a pilot and measure FPY, defects and customer complaints.
A handful of facts
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steps in the TWI Job Quality method
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pillars of self-inspection: instructions, a defect catalogue and OK/NOK reference samples
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goal: quality built directly into the process
Implementation support
We provide support based on the Kata process, which allows us to adapt our activities to the specifics of your organization, taking into account the jointly set goals. The Kata process consists of four key elements that enable effective implementation of assumptions.
We operate according to PDCA
P
PLAN
TWI Job Quality Training begins with thorough process preparation. The team identifies where a defect could arise, which characteristics are critical and what operators need to assess the quality of their own work correctly.
- We select an actual operation and define the customer’s product and process requirements.
- We identify quality key points, special characteristics and the risks of defects occurring or being passed on.
- We define clear OK/NOK criteria, measurement methods, inspection frequency and a standard response.
- We prepare the workstation, quality reference samples, a catalogue of known defects, work instructions and baseline data: FPY, defects and customer complaints.
D
DO
In the DO stage, participants deliver quality training directly at the workstation. Employees learn not only how to perform the operation, but also the required result, inspection points and the reasons behind each requirement.
- The trainer demonstrates the operation, emphasising quality key points and the consequences of overlooking them.
- The participant compares correct and defective work using OK/NOK reference samples, measuring tools and the defect catalogue.
- The employee performs the task independently, describes the quality criteria and explains why they matter.
- We practise the standard response: stopping the process, containing the product, escalating the issue and documenting the non-conformity.
C
CHECK
The CHECK stage verifies whether employees can maintain quality during normal work, including changes in pace, material batches or process conditions. Having instructions available is not enough: what matters is actual behaviour at the workstation.
- We observe several consecutive cycles and how employees carry out self-inspection.
- We verify OK/NOK recognition, the use of measuring instruments and the response to a deviation.
- We compare results with baseline data: FPY, defect levels, recurring defects and the number of problems stopped at source.
- We provide brief feedback precisely where the deviation occurs and distinguish a knowledge gap from a problem in the standard or process.
A
ACT
In the ACT stage, we turn observations into lasting improvements. Recurring non-conformities signal a need to improve the process, instructions or safeguards, rather than simply reminding the operator of the requirements again.
- We analyse the causes of deviations and update quality key points, OK/NOK reference samples and the defect catalogue.
- We simplify inspection and design poka-yoke solutions that reduce the possibility of making or passing on an error.
- After changing the standard, we retrain employees and confirm their competence in practice.
- We transfer effective solutions to similar operations and review results within an agreed quality management rhythm.
Want to learn more? Contact us!
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