Gemba Partner Kaizen Study Japan Program - 2015

GEMBA PARTNER KAIZEN MANAGEMENT CONSULTING /www.gembapartner.com
KAIZEN STUDY JAPAN - 2015

The
Kaizen
Japan
Study
Tour

While
not
only
Europe
but
many
regions
around
the
world
are
suffering
because
of
the
severe
and
well-‐known
financial
and

economic
crisis,
it
is
important
to
act
for
the
recovery
and
future
growth
of
the
companies’
business.
In
Japan,
aBer
many

years
of
sluggish
expansion
and
natural
disasters,
many
companies
are
actually
increasing
their
compeDDveness
in
the

manufacturing
field
even
in
comparison
with
the
low
cost
labor
countries.
TPS
(Toyota
ProducDon
System)
led
Kaizen
in

quality,
producDvity,
cost
and
Dme
reducDon,
environment
friendly
technologies…
are
improving
company
profits
and
image.

That
is
why
we
think
that
a
study
and
training
tour,
visiDng
some
process
and
assembly
industry
plants
of
these
Japanese

organizaDons
could
help
western
companies
to
get
some
hints
and
lessons
to
learn.

Why
Does
"The
Kaizen
Japan
Study
Tour"
Work
for
You?

Characteris=cs
of

"The
Kaizen
Japan
Study
Tour"

ü 
EducaDon
and
Assistance
by
Experts
and
Consultants
with
TPM
and
TPS

Background

ü 
Seminars
and
Kaizen
Training
by

ex

Toyota
Motor
Managers
and
Trainers

ü 
Case
Examples

ü 
Factory
visits

ü 
Small-‐Group
Tour

to
Lead
ParDcipants
to
SubstanDal
Output

Objec=ves
of
"The
Kaizen
Japan
Study
Tour"

ü 
To
Study
the
Background
and
Structure
of
Toyota
ProducDon
System
and
Other

Japanese

Methodologies

ü 
To
Share,
Analyze
and
Solve

Together
Problems
ParDcipants
May
Have

ü To
Have
a
Tour
to
The
World's
Highest
Level
Factories

ü To
Learn
about
Japanese
Culture
and
the
Background
of
its
Excellent
ProducDon
Systems

The
Kaizen
Japan
Study
Tour
Sample
Schedule

Day Time Program Hotel
02/15 Arrival at Kansai Airport TK 046 18:55 Toyota Castle Hotel
(Sun) Transfer to Nagoya and Check-in Hotel Toyota
02/16 Free time Toyota Castle Hotel
(Mon) 17:00 Schedule Explanation Toyota
02/17 09:00-12:00
TPS Work-shop Training Session
①-TPS lecture by ex-Toyota trainers
Toyota Castle Hotel
(Tue) 13:30-15:40 Visit　1： Toyota Motor Co. Toyota
02/18 09:00-12:00 ②-Standard Work and Execution of Kaizen by ex-Toyota trainers Toyota Castle Hotel
(Wed) 13:00-17:00 ③-Standard Work and Execution of Kaizen by ex-Toyota trainers Toyota
02/19 09:30-11:30 Visit 2: Mitsubishi Electric Toyota Castle Hotel
(Thu) 14:00-16:00 Visit 3: Yazaki Kakoh Toyota
02/20 09:00-12:00 TPM seminar Mr. Matsumoto Daiwa Roynet Hotel Shin-Yokohama
(Fri) 14:00-16:00 Visit 4: AVEX Nagoya Plant after transfer to Yokohama Yokohama
02/21 10:00-12:00 Visit 5: Toyota Logistics Daiwa Roynet Hotel Shin-Yokohama
(Sat) PM Sightseeing/Shopping in Tokyo or Yokohama Yokohama
02/22 06:50 Leave for Turkey from Narita Airport TK 051 10:25
(Sun) Arrival Turkey at

The
Japan
Kaizen
Study
Mission
–
Workshop
Training

HIRAYAMA
Training
Center
–
TPS
Dojo
-‐

This
course
will

①　acquire
the
ability
as
managers
&
supervisors
to
execute
Kaizen
by
yourself

②　acquire
TPS
fundamental
knowledge

③　execute
Genchi,
Genbutsu
principle
and
see
actual
work
site
of
skills
to
detect
MUDA,
MURA
and
MURI

④　experience
and
master
Kaizen
technique
by
execuDng
moDon
analysis
using
the
model
producDon
line.

Workshop
Training

Review
of
TPS
and
Kaizen
in
Toyota
way

ExplanaDon
and
PracDce
of
Standard
work
sheet
&
CombinaDon
chart

Finding
problems
from
radiator
assembly
line

DetecDon
of
MUDA,
MURA,
MURI
and
Kaizen

Kaizen
Discussion

Web
URL
:
hIp://www.genbakaizen.com

The
Kaizen
Japan
Study
Tour
–
Company
Profile

TOYOTA
Motor
CorporaPon

Toyota
Motor
CorporaDon,
Japan`s
#1
carmaker
creates
cars,
pickups,
minivans,
and
SUVs
which
include

such
models
as
Camry,
Corolla,
4Runner,
Land
Cruiser,
Sienna,
the
luxury
Lexus
line,
the
Scion
brand,

and
the
hybrid
brand.
Toyota
sells
its
vehicles
in
more
than
170
countries
and
regions
worldwide.

Toyota`s
primary
markets
for
its
automobiles
are
Japan,
North
America,
Europe
and
Asia.

Toyota
also
makes
forkliBs
and
manufactured
housing,
and
offers
consumer
financial
services.

They
have
a
driving
ambiDon
to
become
greener.
The
company
makes
a
hybrid-‐powered
(gas
&
electric)

sedan-‐the
Prius-‐
that
is
being
snapped
up
in
US
and
European
markets.

<Tour
Schedule>

13:30-‐14:40

Toyota
Welding/Assembly
plant

14:40-‐15:00

Transfer
to
the
ExhibiDon
center

15:00-‐15:40

Toyota
Kaikan
ExhibiDon
Center

Date
of
Establishment
:
August,
1937

Number
of
Employees
:
338,875
employees

Products
:
Automobile,
Housing,
Finance/Banking,
etc

Web
URL
:
hIp://www.toyota.co.jp

The
Japan
Kaizen
Study
Mission
–
Discussion
and
Q&A
Session

Mitsubishi
Electric
CorporaPon

The
Mitsubishi
Electric
Group
operates
on
the
corporate
principle
of
contribuDng
to
creaDng
a

vibrant
and
aﬄuent
society
by
enhancing
its
technologies,
services,
and
creaDve
powers,
as
a
leader

in
the
manufacture
and
sales
of
electric
and
electronic
equipment
used
in
energy
and
electric

systems,
industrial
automaDon,
informaDon
and
communicaDon
systems,
electronic
devices,
and

home
appliances.

Mitsubishi
Electric
CorporaPon’s
Nagoya
Plant
is

the
company’s
principal
facility
for
automaDon

equipment
producDon,
ensuring
supplies
of
key
parts
to
Mitsubishi
Electric’s
factory
automaDon

lines
worldwide.

ProducDon
of:
heavy
electric
machinery
systems,
industrial
mechatronics,
informaDon
and

telecommunicaDons
systems,
electronic
devices,
manufacturing
and
sales
of
home
electric

appliances,
etc.

Mitsubishi
Electric
Group

Founded:
January
,
1921

Employees:
124,305
(Group
total),

1,970
(Nagoya
works)

Annual
turnover:
4,054
billion
Yen

(USD
44.4
Billion
in
a
rate
of
1USD=
82
JPY)

URL:
hIp://www.mitsubishielectric.co.jp/

The
Kaizen
Japan
Kaizen
Study
Mission
–
Company
Profile

YAZAKI
KAKO
Co.

Today’s
manufacturers
are
challenged
to
increase
producDvity
while
lowering
manufacturing
costs.
Properly

employed,
the
dynamics
of
conDnuous
improvement
and
lean
manufacturing
can
result
in
a
10%
increase
per
year
in

producDvity
by
eliminaDng
non-‐value
added
waste.
Yazaki
assists
customers
implement
conDnuous
improvement
and

lean
programs
as
well
as
the
five-‐S
ideology
and
eliminaDon
of
non-‐value
added
waste
using
the

Karakuri
/
Creform

System.

Main
Business:

Manufacture
and
machining
of
injecDon
molded,
plasDc
products,
electrical
appliances
and
roducDon

machinery.

Date
of
Establishment
:

Oct
,
1953

Number
of
Employees
:

940

Sales
Revenues:
20.2
Billion
Yen

Web
URL
:
hIp://www.yazaki.co.jp/profile/gaiyo.html

The
Japan
Kaizen
Study
Mission
–
Discussion
and
Q&A
Session

Company PosiPon Experience
Toyota
Motor
Corp.
FaciliDes
Dept.
MoDve
Power
Div. ・Maintenance
of
Press
and
Body
Factory

Toyota

Motomachi

Factory

Engineering
Dept.
Building
Equipment

Div.

-‐Leader
・Maintenance
of
PainDng
and
ConstrucDng

Factory
Grand
Assembly
Dept.
Maintenance
Div.

-‐Manager
・Maintenance
of
PainDng
and
ConstrucDng

Factory
Measuring
Div.
in
Head
Quarter ・Brought
the
Measuring
Machine
of
Vehicle’s

Exhaust
Gas
Product
Inhouse.

Kuozui
Motors
Ltd.
In
Taiwan ・Supported
the
maintenance
of
PainDng
and

ConstrucDon
TKM（India）・Supported
the
Establishment
of
the
Factory
TMCA（Australia）・Supported
Maintenance
of
PainDng
and

ConstrucDng
Factory
ASSB（Malaysia）・Supported
Maintenance
of
Whole
Factory
Global
PromoDng
Center ・Promoted
ExplicaDon
of
Knowledge
of

Maintenance.

・Supported
the
Establishment
of
Training
Center

for
Maintenance
Engineer
in
China（Tianjin,

Guangzhou）,England,
North
America
and
India
TPM
Consultant

Mr.
Yoshikatsu
Matsumoto

Under
the
moto:
“The
development
of
a
company
starts
with
the
development
of
human
resources,”

AVEX
trains
engineers
who
can
machine
and
grind
components
on
a
micron
scale.

Their
high
skills
enable
AVEX
to
operate
an
integrated
system
to
produce
everything
from
prototypes

to
mass-‐produced
products.

Since
fiscal
2006,
AVEX
was
selected
as
one
of
the
“A
SelecDon
of
300
of
Japan's
Monozukuri

(Manufacturing)
SMEs”.

Hydraulic
control
valves
for
automoDve
automaDc
transmission
systems
require
extremely
high
precision

to
ensure
their
accurate
sliding
movement
in
the
systems.
The
valve
outer
diameter
tolerance
must
be

within
just
+/-‐0.0008
mm.
The
smooth
acceleraDon
and
deceleraDon
of
automaDc
cars
depends
on

our
technologies
embodied
in
these
valves
that
are
almost
the
same
size
as
a
finger.

<Tour
Schedule>

14:00-‐14:30

Company
IntroducDon

14:30-‐15:30

Plant
Tour

15:30-‐16:00

Q&A

Establishment
:

1953

Employees
:

303
employees

Products
:

AutomoDve
Parts
(A/T
valves,
Breaks,
Engine
Parts,
etc.)

Web
URL
:

htp://www.avex-‐inc.co.jp

AVEX

The
Kaizen
Japan
Kaizen
Study
Mission
–
Company
Profile

TOYOTA
L&F
(LogisPc
&
Forklin)

Toyota
L&F
carries
out
the
LogisDcs
SoluDons
Business
to
help
companies
reduce
their
logisDcs
costs.

and
handles
all
aspects
of
customers'
logisDcs
by
combining
our
extensive
business
experience
in
forkliBs,

liB
trucks,
automated
storage
and
retrieval
systems,
and
other
materials
handling
equipment
with
our
producDon

and
logisDcs
know-‐how
that
has
been
culDvated
from
monozukuri
(creaDng
things).

TOYOTA
L&F
is
building
original
business
models
that
strive
to
opDmize
the
overall
ﬂow
of
“goods”,
“money”,

and
“informaDon”
from
the
manufacturer
to
the
customer,
and
thereby
contribute
to
the
opDmizaDon
of

the
customer's
overall
logisDcs.

<Tour
Schedule>　Sample

10:00-‐10:30

IntroducDon
of
TOYOTA
L&F
by
Video

10:30-‐11:30

LogisDcs
System

11:30-‐12:00

Q&A
Session

Date
of
Establishment
:
August
15th,
1960

Number
of
Employees
:
709
employees

Products
:
LogisDcs
System
of
Toyota
ForkliBs,
Rental
&
Lease
business

Web
URL
:
hIp://www.toyota-‐lf.com
The
Kaizen
Japan
Study
Tour
–
Company
Proﬁle

Scenes
from
Kaizen
Scenes
Program

Ø 
Schedule
subjected
to
change
The
Kaizen
Japan
Study
Tour

Hotel
InformaPon
Toyota
Castle
Hotel

-‐
Toyota

February

16
(Mon)
-‐
19
(Thursday)

Address:
COMO
square
West,
Kitamachi
2-‐160

Toyota
city,
Aichi
Prefect.,
471-‐0027

Tel:
+81-‐565-‐31-‐2211

Daiwa
Roynet
Hotel
Shin-‐Yokohama

February

20
(Friday)
-‐
21(Sat)

Address:
3-‐17-‐1,
Shin-‐yokohama,
kohoku-‐ku,
Yokohama-‐shi,

Kanagawa
222-‐0033

Tel:
+81-‐45-‐473-‐4155

ParPcipaPon
Fee
(To
pay
one
month
before
the
tour
starDng)
:

The
fee
includes
:

Ø 

Hotel
AccommodaDon
for
6
nights
with
breakfast
and
lunch

Ø Arrangements
for
factory
visits
escorted
by
Hirayama
Staff

Ø 

TransportaDon
during
the
tour,
including
company
visits
and
sightseeing

Ø 

EducaDon
materials
and
text
books

Ø 
Hirayama
Staff
assistance
and
cultural

inputs
during
the
tour

The
fee
excludes
:

• 

Travel
to
and
from
Japan
(Airfare)

• 

TransportaDon
to
and
from
the
airport
in
Japan
(if
not
in
the
same
group)

• 

Interpreter’s
fee
during
the
training
program
and
factory
visits

• 

Travel
insurance
and
alcohol
drinks
during
meals
or
elsewhere

• 

Incidentals
(telephone
calls,
addiDonal
drinks,
laundry,
etc.)
Tour
Details

Dates
–

7
days
,

6
nights

from
February

16
to
22

The
parDcipants
will
arrive
at
the

Nagoya
Airport
on

Monday.
If
they
arrive
in
the
morning
as
group,
the
will
go
to

Hotel
by
Limousine
Bus
and

atend

the
Tour
introducDon
and
evening
dinner.
On
the
return
trip,
parDcipants
will

depart
from
Tokyo
InternaDonal

Airport

on
Sunday.
It
is
possible
to
add
some
extra
days

before
or
aBer
the
Tour,

for
personal
reasons.
Hirayama
staff
will
help
from
the
logisDc
standpoint
but
the
expenses
will
be
paid
personally.

CancellaPon
Policy

•
30
days
prior
to
the
starDng
date
of
the
tour

No
charge

•
29
–
16
days
prior
to
the
starDng
date
of
the
tour

30%
of
the
tour
fare

•
15
–

8
days
prior
to
the
starDng
date
of
the
tour
　　　　　　　　　　　50%
of
the
tour
fare

•

7
days
prior
to
the
starDng
date
of
the
tour

100%
of
the
tour
fare

The
Kaizen
Japan
Kaizen
Study
Mission
Tokyo
InformaPon

Tokyo,
the
capital
of
Japan,
is
one
of
the
largest
ci;es
of
the
world
with
a
popula;on
of
13.00-‐million
and
the
biggest
of
the
47

prefectures
throughout
Japan.
Its
long
history
of
prosperity
started
with
the
establishment
of
the
shogunate
by
Tokugawa
Ieyasu
in

1603.
At
that
;me,
Tokyo
was
called
Edo,
which
by
the
18th
century
had
grown
to
a
huge
city
of
over
a
million
people.
It
is
now

Japan's
center
for
poli;cal,
economic,
cultural,
and
various
other
ac;vi;es
as
well
as
the
origin
for
the
dissemina;on
of
informa;on

The
Imperial
Palace
is
now
the
residence
of
the
emperor.
However,
there
used
to

be
Edo
Castle
on
this
site
and
many
samurai
warriors
and
horses
were
always

going
in
and
out
of
the
castle
grounds.
The
beau;ful
Nijubashi
Bridge
is
the
best

place
for
taking
a
commemora;ve
photo
at
the
Imperial
Palace
A
big
red
lantern
hangs
under
this
gate,
which
is
magnificent!
Behind

the
gate
is
the
approach
to
the
main
hall
of
Senso-‐ji
Temple,
along

which
stand
many
restaurants
and
shops
where
you
can
enjoy
all
sorts

of
Japanese
things
such
as
Japanese
sweets
or
purchase
of
a
yukata

(Japanese
summer
Kimono.
This
is
the
most
high-‐end
shopping
area
in
Japan!
You
also

shouldn't
miss
the
aXrac;ve
architectural
designs
of
pres;gious

brand
buildings,
including
Louis
VuiXon
and
Hermes.
The
area

has
a
refined
atmosphere
of
adults,
and
is
home
to
venerable

department
stores
such
as
Mitsukoshi
The
height
of
the
TOKYO
SKYTREE
was
originally
specified
at
approximately
610m
in
the
original
project.

However,
it
was
planned
from
the
beginning
to
be
the
world's
tallest
free-‐standing
broadcas;ng
tower.
Aêr

careful
discussion
and
research
on
high-‐rise
buildings
that
are
being
built
around
the
world,
it
was
finally

decided
on
634m,
to
become
the
tallest
free-‐standing
broadcas;ng
tower
in
the
world.

Thus,
the
634m-‐high
TOKYO
SKYTREE
was
recognized
by
the
Guinness
World
Records
Company
on
November

17,
2011
as
the
tallest
tower
in
the
world.

The
Kaizen
Japan
Kaizen
Study
–Toyota
City
InformaPon

Toyota
City
is
home
to
Toyota
Motor
Corpora;on
headquarter
and
factories,
and

more
than
400
car-‐related
companies
with
various
engineers
the
technology
is
always

evolving.
In
addi;on,
there
is
the
Obara
Japanese
paper
along
with
the
tradi;onal

skills
that
cra^smen
kept
and
con;nue
to
pass
on
to
next
genera;ons.

Toyota
City
is
the
largest
city
in
Aichi
prefecture,
the
lowest
land
point
is
located
in
Komashin-‐cho
(3.2m)
and
the
highest
is

located
in
Inabu-‐cho
(1,240m).
The
1,200m
difference
makes
the
town
full
of
hills.
Around
the
sta;on
you
will
find
a
cityscape

and
gentle
natural
sceneries.
The
views
joining
the
opposite
paths
of
low
and
highlands.
This
is
an
endless
travel
to
a
place

where
“From
one
to
another,”
”From
the
past
to
present”
and
“From
someone
to
anyone”
con;nues.

The
fluctua;ng
yearly
temperature
and
different
al;tudes
make
four
seasons

sceneries
of
Toyota
City
more
appealing.
As
the
new
season
comes
the
scenery

changes,
as
the
al;tude
elevates
the
expression
changes.
This
Toyota
City
is

worth
travelling
all
year
round.

Toyota
City
was
first
called
Koromo.
That
history
also
appears
at
the
oldest
surviving

book
known
as
“Kojiki”
or
the
Records
of
Ancient
MaXers.
Matsudaira-‐go
is
where

the
Tokugawa
clan
was
founded
and
the
birthplace
of
Matsudaira,
while
Asuke
is
the

distribu;on
point
thru
Ina
road.
The
town
surrounding
the
remains
of
Shichishu
Castle

can
remember
the
Koromo
Domain’s
twenty
thousand
Goku.
In
a
place
where

memories
of
ancient
people
are
le^,
try
to
enter
and
solve
the
puzzles
of
history
back

then.

The
Kaizen
Japan
Kaizen
Study
–
Nagoya
InformaPon

Food:
Nagoya
is
famous
for
its
miso
sauce
cuisine
and
tebasaki
.
Famous
plates
are

kishimen
noodle,
miso-‐katsu
cutlet,
and
tebasaki
fried
chicken
wing;ps.

Nagoya
City,
located

at
the
center
of
Japan,
is
capital
of
Aichi
Prefecture
in
Chubu
Region
and
one
of
the
three
major

metropolitan
regions
(Tokyo,
Osaka,
and
Nagoya).

Greater
Nagoya,
centralized
in
Nagoya
City,
is
the
hub
of
Japanese
manufacturing
industries,
producing
over
40%
of
major

manufacturing
categories
such
as
automobiles,
automobile
parts,
machine
tools
and
aircra^
parts,
and
exerts
its
role
as
a

strong
leader
in
the
Japanese
economy.

Popula;on:

2,263,907
inhabitants

Economy:
Greater
Nagoya
GDP（459
billion
USD)
is
placed
18th
comparing
with

the
world's
countries.

Access:
By
road
(Expressway)
-‐
Tokyo,
325
km
/
Osaka,
183
km

By
bullet
train
(each
10
min)
-‐
Tokyo,
95
minutes
/
Osaka,
50
minutes

By
air

-‐
Central
Japan
Interna;onal
Airport
(domes;c
and
interna;onal
lines
)

By
sea
-‐
Nagoya
Port
(Japan‘s
largest
port)

Climate
and
clothing:

The
temperature
rarely
drops
below
0°C
in
the
plains
along
the

Pacific
coast
during
winter;me.
It
is
also
quite
dry
and
very
oên
sunny.
The
weather
is

fair
and
the
average
temperature
in
Nagoya
varies
between

0
C

and
10
C

in
Februray.

Tourist
Spots:

Nagoya
Sta;on
Area
(business
area
and
modern
buildings)
,
Nagoya
Castle

Area
(government
and
public
offices
)
,
Sakae
Area
(Shopping,
fashion
and
night
life),

Shirakabe
(the
most
powerful
Shogun
family

“Tokugawa”
origin)


OrganizaPon

GEMBA
PARTNER
KAIZEN

MANAGEMENT
CONSULTING

İSTANBUL
-‐
TURKEY

www.gembapartner.com

CONTACT:

Atakan
Zehir

info@gembapartner.com

The
Japan
Kaizen
Study
Mission
–
Contact

Please
feel
free
to
contact
us
for
further
ques=ons.

Gemba Partner Kaizen Study Japan Program - 2015

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