1. The Japanese
Productivity
Philosophy and Practices
A summary and re-presentation for:
A Study Mission Report
JAPANESE PRODUCTIVITY
By: John M. Burnham, CPIM, Tennessee Technological University
Published by: APICS, 1983
© 2009 Factory Strategies Group LLC. All rights reserved.

2. Outline
1. Philosophy
2. The Japanese worker
3. Inventory Management
4. Vendor Relations
- KANBAN
5. Technology
6. Challenges
7. Conclusion
© 2009 Factory Strategies Group LLC. All rights reserved. 2

3. 1. Philosophy
1. Simplicity
2. Holistic view
3. Excellent plan execution
4. Respect and teamwork
5. Continuous improvement
6. Balance: productivity and quality
(higher quality = less waste = lower costs = higher productivity)
© 2009 Factory Strategies Group LLC. All rights reserved. 3

4. The Japanese
Productivity
© 2009 Factory Strategies Group LLC. All rights reserved. 4

5. 2. The Japanese Worker
• Attitude
• Employees
• Managers
• The interaction
• Money
• Motivation
• Training and Job Rotation
© 2009 Factory Strategies Group LLC. All rights reserved. 5

6. 3. Inventory Management
• Very low inventory
• Scheduling
• Uploading
• Delivery
• Unloading
© 2009 Factory Strategies Group LLC. All rights reserved. 6

7. 4. Vendor Relations
• Close relations
• Information sharing
• Vendor close to the user
© 2009 Factory Strategies Group LLC. All rights reserved. 7

8. Production and Inventory Control
KANBAN
• What is it?
It’s a signalling system to trigger action
• The essential elements of KANBAN:
1. Stockpoint(s)
2. A Withdrawal Signal
3. Immediate Feedback
4. Frequent Replenishment
© 2009 Factory Strategies Group LLC. All rights reserved. 8

9. Production and Inventory Control
KANBAN
• When to use KANBAN?
• Benefits
© 2009 Factory Strategies Group LLC. All rights reserved. 9

10. Production and Inventory Control
KANBAN
• Challenges
• e- KANBAN
© 2009 Factory Strategies Group LLC. All rights reserved. 10

11. 5. Technology
• Tools
• Computer technology
• Preventive maintenance
© 2009 Factory Strategies Group LLC. All rights reserved. 11

12. 6. Challenges
• Truck transportation
• Workforce
• The protectionist Japanese policy
© 2009 Factory Strategies Group LLC. All rights reserved. 12

13. Remark
“The Japanese people appear to be very clean. Litter is
particularly non-existent”
Burnham
© 2009 Factory Strategies Group LLC. All rights reserved. 13

14. A new
mission
© 2009 Factory Strategies Group LLC. All rights reserved. 14