Tecnotion is the global authority on direct drive motor technology. The Almelo-based company specializes in the development and production of direct drive motors. Tecnotion serves a number of high-growth market segments, including semicon, LCD/LED manufacturers, laser printing and robotics industries.

“We have known Symbol for years as a fine knowledge partner to work with,” begins Alwin Wessels, Quality Manager Operations at Tecnotion. “For our Operational Excellence ambitions, we have already successfully relied on Symbol on a regular basis. In 2018, for example, Symbol conducted a CIMM scan at our Almelo and China sites and helped us set up an OpEx roadmap. We also like to use Symbol’s junior consultants, who are quickly deployable and quickly up-and-running.
In the past year we have already worked with a junior consultant three times, including Hans van de Vijver. Hans recently implemented Training Within Industry (TWI) in the organization for us.”

Operators are the most important capital

“An increase in production personnel had greatly increased the need for a standardized training method within our organization,” Alwin continues. “Previously, there was no uniformity in teaching skills and didactics were almost not considered. From other organizations, we knew that Training Within Industry (TWI) could be the solution. TWI is a strong method for standardized, effective and efficient training. For us, this is necessary to give new operators from various industries – with different backgrounds and talents – the same knowledge and competencies. In this way we increase our reliability towards critical customers such as ASML, VDL and NTS, among others.”

Train new employees uniformly

TWI has been implemented in two phases within Tecnotion. The first phase consisted of knowledge transfer and training TWI trainers. The second phase, currently in progress, focuses on implementing and making TWI fit into the processes already in place. Hans was responsible for the first phase. “TWI originated in World War II, when large groups of new workers had to be inducted into the American steel mills in a short period of time. Today, it is still a perfect tool to use to speed up the training process and make it more effective. TWI consists of four components: job methods, job instruction, job safety and job relations. Because of Tecnotion’s specific issue, my focus was on job instructions.

TWI instructors certified

Hans continues, “From an A3 project charter, the TWI project was outlined and the kick-off was given to the core team. Together with the core team, we started drafting and handling job instructions in the first weeks of the project, in order to gain initial knowledge in the TWI working method. Then I also provided TWI training to the core team. After this practical and theoretical training, the team started working on their own to create and instruct task instructions. Supervising the trainers and ensuring that the TWI method was closely followed was very important at this stage. After all, when certain steps are skipped, job instruction is pointless and we miss our goal. We monitored the acquired TWI skills from a competency matrix. With that matrix, it was possible to see who needed individual counseling on which subjects. Through the efforts of the TWI trainers and individual coaching, everyone was prepared for certification. Very nice to see that everyone was so motivated and made strides so quickly!”

Training Within Industry is change management

“Implementing TWI without applying change management is impossible,” Alwin adds. From experience, we knew that TWI could be successful within our organization. But changing an existing way of working overnight does not work. The key to change management was primarily in communication – engaging with each other and listening to each other. After all, you can’t build support if you don’t engage with your stakeholders. Hans has been instrumental in the change aspect within the TWI project. He clearly transferred TWI knowledge to the core team, listened to them well and could empathize with them – but he always stuck to the TWI method. Through the efforts of Hans and the core team, all eight TWI instructors successfully completed the training. Consequently, all instructors earned their “TWI trainer” certification. The certification was an important milestone in the TWI project and we celebrated with a piece of cake.”

From project to mature system

After completing the first phase of the TWI project, Hans passed the baton to an internal Continuous Improvement Engineer. Alwin: “Implementing TWI in the current training program and further developing task instructions are central to this. Due to expected growth, in the first quarter of 2023, Tecnotion will train 40 operators using TWI. A good baptism of fire, which we look forward to with confidence.”

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