Imagine going from a small, close-knit team of 25 to a bustling workforce of 160 in just a few months. Sounds exciting, right? It is. But it’s also a massive challenge. This was the exact situation one of our clients recently faced. They’d landed a huge contract, demanding rapid expansion and a dramatic shift in their production model.

The Problem: Rapid Growth, Rapid Change

Moving from “craftsman-style production” to a streamlined, efficient manufacturing operation isn’t easy. Suddenly, you need to:

• Quickly train a flood of new employees.
• Equip new supervisors to lead effectively.
• Maintain (or even improve!) quality and delivery standards.

Our client knew they needed a solution, and fast. They chose to partner with us and implement a game-changing approach: Training Within Industry (TWI).

Our Solution: Unlocking Efficiency with TWI

We introduced our client to two powerful TWI patterns: Job Instruction (JI) and Job Methods (JM). These aren’t just training programs; they’re frameworks for building a culture of continuous improvement.

• Job Instruction (JI): We empowered their team to train new hires faster and more effectively, minimizing errors and boosting confidence. This wasn’t just about teaching tasks; it was about fostering a culture of competence and engagement.
• Job Methods (JM): We helped them streamline and standardize their production processes, leading to higher quality, faster output, and better utilization of resources. It also created a system where everyone could contribute ideas for improvement.

The Results: More Than Just Growth

The impact was immediate and profound.

• Rapid Onboarding: They effectively trained a huge influx of new employees, ensuring everyone was productive from day one.
• Empowered Leadership: Supervisors developed the skills to manage their teams confidently and efficiently.
• Quality and Consistency: Production processes were standardized, guaranteeing reliable results and meeting (and exceeding) quality standards.

But the best part? The Client Project Manager said TWI is now a fundamental part of their culture. It’s not just a training program; it’s how they do business. They see it boosting retention, fostering fairness, and driving continuous development.

The Numbers Speak for Themselves

In the following 12 months, the client anticipated some impressive results:

• $30M in Increased Sales
• $40M in Retained Sales
• 160 New Jobs Created
• $5M in Cost Savings
• $1.75M Increased Investment in Plant and Equipment

And that’s just the beginning!

Ready to Scale Your Business?

Whether you’re facing rapid growth, looking to improve efficiency, or aiming to build a stronger company culture, our TWI solutions can help. We specialize in providing structured training and process improvement tools that empower your team and drive tangible results.