Khóa đào tạo TPS Kaizen Tour 2015

Copyright (C) 2015 HIRAYAMA Co.,Ltd. All Rights Reserved. URL http://www.genbakaizen.com
HIRAYAMA Consulting
The Japan Kaizen Tour
Mansion
Page 1

HIRAYAMA – The Japan Kaizen Tour
The Toyota Production System is considered to be the final production control method, which has led Toyota Motors to be the
most competitive motor company in the world. Every company in the world today is interested in whether to implement the
Toyota Production System to their system. We organized, "The Japan Kaizen Tour", to see the current status of its place of birth,
at Toyota Motors. We offer seminars, on-site Kaizen training, and what's more, a factory tour at the world-leading facility for
structure and management of the Toyota Production System.
Why Does "The Japan Kaizen Tour" Work for You?
Characteristics of "The Japan Kaizen Tour"
 Training by Consultants with a Toyota Motors Background
 Seminars and Kaizen Training
 Case Examples
 A Factory Tour
 Small-Group Tours of under 20 Participants to Lead to Substantial Output
Objectives of "The Japan Kaizen Tour"
 To Study the Background and Structure of Toyota Production System
 To Analyze and Solve any Problems Participant's May have Together
 To Have a Tour of The World's Highest Level Factory
 To Learn About Japanese Culture and the Background of the Toyota Production System
 To Allow for Communication Between Fellow Seminar Members
Page 2

Day 1
1st Sun
Day 2
2nd Mon
Day 3
3rd Tue
Day 4
4th Wed
Day 5
5th Thu
Day 6
6th Fri
Breakfast
Pick up at Nagoya
airport
Breakfast Breakfast Breakfast Breakfast Breakfast
Plant Tour
Debriefing in
Nagoya
(Nagoya Castle )
TPS Dojo
Workshop 1
Toyota Motors Mirai Industry Omron
Leave hotel for
Osaka Airport
Depart for
Vietnam
Study Topic
Basic concept of
TPS. Standardized
work in TPS
Final Assembly line,
Welding by Robot
(Center of TPS –
JIT, Jidoka)
5S, TPS, Kaizen
Activity
5S, TPS, Kaizen
Activity
Lunch Lunch Lunch Lunch Lunch Lunch
Plant Tour
・Toyota Techno
Museum
・Check in hotel &
Free
TPS Dojo
Workshop 2
Mitsubishi
Electronics
Daifuku
Debriefing in Kyoto
Shopping
Study Topic
Spinning and
Weaving Technology
Automobile
Technology and
Industry
Detect waste &
Kaizen method
Energy & Electric
Systems, Industrial
Automation System,
etc
QC Circle ,
5S,Visual
Management,
Kaizen Activity
The Japan Kaizen Tour Schedule (6days – 5nights)
Copyright (C) 2015HIRAYAMA Co.,Ltd. All Rights Reserved. URL http://www.genbakaizen.com
1st 24/05 ~ 29/05/2015 2nd 16/08 ~ 21/08/2015 3rd 15/11 ~ 20/11/2015
Page 3

Day 1
1st Sun
Day 2
2nd Mon
Day 3
3rd Tue
Day 4
4th Wed
Day 5
5th Thu
Day 6
6th Fri
Day 7
7th Sat
Breakfast
Pick up at
Nagoya airport
Breakfast Breakfast Breakfast Breakfast Breakfast Breakfast
Plant Tour
Debriefing in
Nagoya
(Nagoya Castle )
TPS Dojo
Workshop 1
Toyota Motors
Toyota
Techno
Museum
AVEX
Omron
Leave hotel
for Osaka
Airport
Depart for
Vietnam
Study
Topic
Basic concept of
TPS.
Standardized
work in TPS
Final Assembly
line, Welding by
Robot
(Center of TPS –
JIT, Jidoka)
Spinning and
Weaving
Technology
Automobile
Technology
and Industry
5S, TPS, Kaizen
Activity
5S, TPS, Kaizen
Activity
Lunch Lunch Lunch Lunch Lunch Lunch Lunch
Plant Tour
・Check in hotel
・Free
TPS Dojo
Workshop 2
Mitsubishi
Electronics Mirai Industry
Daifuku
Debriefing in
Kyoto
Shopping
Study
Topic
Detect waste &
Kaizen method
Energy & Electric
Systems,
Industrial
Automation
System, etc
5S, TPS, Kaizen
Activity
QC Circle ,
5S,Visual
Management,
Kaizen Activity
The Japan Kaizen Tour Schedule (7days – 6nights)
Copyright (C) 2015HIRAYAMA Co.,Ltd. All Rights Reserved. URL http://www.genbakaizen.com
1st Aug 23~Aug 29, 2015 2nd Nov 22~Nov 28, 2015
Page 4

The Japan Kaizen Tour – Company Profiles
TOYOTA Techno Museum
The Museum was founded in a cooperation of 13 companies of Toyota Group, and uses the location
and buildings of Toyota Bouseki’s main office, the origin place of TOYOTA. The museum's mission is
to systematically introduce the history of Japanese manufacturing technology to those who will be
responsible for its future development and the evolving world of automobile engineering.
Summary of the exhibition facilities:
1. Textile Machinery Pavilion – Spinning and Weaving Technology
2. Automobile Pavilion – Automobile Technology and Industry
Automobile Mechanisms and Component Parts, development of
automobile and production technology
Material laboratory, prototyping plant
Address: 4-1-35, Noritake Shinmachi, Nishi-Ku, Nagoya City
Web URL: http://www.tcmit.org
Page 5

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 executing motion analysis using the model production line.
<Schedule> Workshop Training
9:00- 10:30 Introduction of TPS and Kaizen in Toyota way
10:40- 12:00 Explanation of Standard work sheet & Combination chart
12:00- 13:00 Lunch
13:00- 14:00 Finding problems from radiator assembly line
14:00- 15:00 Detection of MUDA, MURA, MURI and group discussion
15:10- 16:10 Rebuilding and implementation of the line
16:15- 17:00 Summary, Q & A Session
Web URL : http://www.genbakaizen.com
Page 6

TOYOTA Motor Corporation
Toyota Motor Corporation, Japan`s 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 forklifts and manufactured housing, and offers consumer financial services.
They have a driving ambition to become greener. The company makes a hybrid-powered (gas & electric)
sedan-the Prius- that is being snapped up in US and European markets.
The company recorded revenues of $221 billion during the fiscal year of 2013, a increase of 18.7% over 2012
and Net profit $14 Billion, a increase of 224.3% over previous year.
<Tour Schedule>
09:30-10:45 Visit Toyota motors (Assembly line & Welding by robot assembly)
10:45-11:45 Visit Toyota Kaikan (Exhibition Hall)
Date of Establishment : August, 1937
Number of Employees : 69,478 employees
Products : Automobile, Housing, Finance/Banking, etc
Web URL : http://www.toyota.co.jp
Page 7

Mitsubishi Electric Corporation
The Mitsubishi Electric Group operates on the corporate principle of contributing to creating a
vibrant and affluent society by enhancing its technologies, services, and creative powers, as a leader
in the manufacture and sales of electric and electronic equipment used in energy and electric
systems, industrial automation, information and communication systems, electronic devices, and
home appliances.
Mitsubishi Electric Corporation’s Nagoya Plant is the company’s principal facility for automation
equipment production, ensuring supplies of key parts to Mitsubishi Electric’s factory automation
lines worldwide.
Production of: heavy electric machinery systems, industrial mechatronics, information and
telecommunications systems, electronic devices, manufacturing and sales of home electric
appliances, etc.
■Overview of the Company
Company name: Mitsubishi Electric Group
Founded: January , 1921
Employees: 117,314 (Group total), 1,970 (Nagoya works)
Annual turnover: 3,639.4 billion Yen
(USD 44.4 Billion in a rate of 1USD= 82 JPY)
URL: http://www.mitsubishielectric.co.jp/
Page 8

Mirai Industry
The company is an electric installation equipment manufacturer and well-known as unique management
by CEO Akio Yamada. More than 10, 000 kaizen improvement ideas per year submitted from employees
and very popular for employee welfare policy, mandatory retirement at the age of 70, no layoff, 140
holidays
a year, overseas travel for all employees every 5 years, no night overtime, 3 years maternity leave, 10 days
off at the year-end holidays and highest salary in the local area. Mirai has a heaven-like working
environment
for employees.
■Overview of the Company
Name Mirai Industry Co., Ltd.
Founded August, 1965
Capital 7,068 Million
Consolidated Net Sales 21,900 Million
Employees: 780 employees
Business lines Electrical equipment materials, Plumbing
sanitary materials, water supply & drainage and gas equipment, etc
URL: http://mirai.co.jp
Page 9

Copyright (C) 2015 HIRAYAMA Co., Ltd. All Rights Reserved. URL http://www.genbakaizen.com
DAIFUKU CORPORATION (Shiga Plant)
Since 1937, Daifuku has focused on material handling – the movement of finished goods and work in progress.
Daifuku’s world-class systems lead the industry by combining conveying, storage, sorting, picking and controls;
products serve customers in a range of industries and countries.
Daifuku's roots lie in automotive factory automation (AFA) with chain conveyers during the advent of motorization.
AFA operations, factory and distribution automation (FADA), cleanroom factory automation for semiconductor and
flat panel displays (eFA), and airport baggage handling (ABH) represent Daifuku's four core business divisions. In
addition, Daifuku has developed car wash machines and unique equipment to improve communities. Daifuku
subsidiary Contec, which is listed on the Second Section of Tokyo Stock Exchange, supplies electronics.
As a leading material handling manufacturer, Daifuku's mission is to develop unique cutting-edge systems for each
customer. Daifuku’s recent achievements include the creation of a distribution center compatible with supply chain
management and transport systems in cleanrooms for manufacturing semiconductors and flat panel displays.
Daifuku assists customers from planning to proposal, design, manufacturing, installation, after-sales service and
facility retrofits.
Daifuku is a global company with non-Japanese sales accounting for 60% of total sales. By strategically locating
production and procurement operations world-wide and by collaborating closely with global network of affiliate
companies and branch offices, provides complete customer support on a global scale.
Date of Establishment : May 20, 1937
Number of Employees : 7,349 (as of March 31, 2014)
Business : Material Handling，
Employing Comprehensive Capabilities – Consulting to Service
URL : http://www.daifuku.com/
The Japan Kaizen Tour– Company Profile Page 10

OMRON Kyoto Taiyo
Omron Kyoto Taiyo with a partnership with Japan Sun Industries have promoted job opportunities
for the disabled under the motto of `No Charity, But a Chance`, by creating supportive working
environment in which the disabled are able to create more chances for socially satisfying lives.
The main philosophy is to derive the underlying potential of the disable and maximizing their
capability by providing mechanical aids including unique supportive jigs and kaizen improvement in
their working environment.
Date of Establishment : 1985
Number of Employees : 19 employees + Handicapped workers
Products : Switches, Socket, Sensor, Battery
Web URL : http://www.kyoto-taiyo.omron.co.jp
Page 11

Under the motto: “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.
In fiscal 2006, AVEX was selected as one of the “A Selection of 300 of Japan's Monozukuri
(Manufacturing) SMEs”.
Hydraulic control valves for automotive automatic 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 acceleration and deceleration of automatic cars depends on
our technologies embodied in these valves that are almost the same size as a finger.
<Tour Schedule>
09:30-10:00 Company Introduction
10:00-11:00 Plant Tour
11:00-11:30 Discussion, Q&A
with Chairman
Date of Establishment : June, 1953
Number of Employees : 140 employees
Products : Automotive Parts (A/T valves, Breaks, Engine Parts, etc.)
Web URL : http://www.avex-inc.co.jp
AVEX
The Japan Kaizen Tour – Company Profiles Page 12

City Information – Nagoya
Food: Nagoya is famous for its miso sauce cuisine and tebasaki . Famous plates are
kishimen noodle, miso-katsu cutlet, and tebasaki fried chicken wingtips.
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 aircraft parts, and exerts its role as a
strong leader in the Japanese economy.
Population: 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 International Airport (domestic and international lines )
By sea - Nagoya Port (Japan‘s largest port)
Tourist Spots: Nagoya Station 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)
Page 13

City Information – Kyoto
Food: Kyoto has its own culinary culture. Located far from the ocean, it was difficult to
get fresh seafood. That's why in the Kyo-ryori (Kyoto cousin) they use dry food,
vegetables and soya bean products. To savor and enjoy these ingredients, various
cooking methods and techniques were invented and in Japanese traditional
restaurants, it became the height of sophistication, creating delicious dishes that
show the seasonal beauty of nature on a plate almost like a work of art.
Kyoto, “Japan’s heartland”, is a city that over a period of 1000 years, dating from the decision to move the capital to Kyoto in 794,
nurtured a unique kind of culture and came to be considered the mother of culture and Japan’s foremost travel destination.
Kyoto was the capital of Japan and the Emperor’s place of residence till the capital was shifted to Tokyo in 1868. Kyoto is a
breathtaking city that offers historical sites, beautiful nature scenes and friendly locals.
Population: 1,473,746 inhabitants
Economy: Information Technology (Nintendo, Omrom, Kyocera),
Tourism and handcrafts
Access: 73 minutes from Kansai Airport by JR "Haruka" Kansai Airport Limited Express
2 h and 22 min from Tokyo Station (Bullet Train)
Tourist Spots: the all city is a touristic spot with dozens of temples and historical sites.
Here are some of them: Kyoto Tower , Kiyomizu-dera Temple, Nijo Castle, Kinkakuji Temple ,
Gion Town, Tetsugaku no michi.
Page 14

Other basic Information
Electricity: The voltage used throughout Japan is uniformly 100 volts, A.C. There are two kinds of
frequencies in use; 50 Hertz in eastern Japan and 60 Hertz in western Japan (including Nagoya, Kyoto and
Osaka). There are no columnar-shaped plugs or 3-pin plugs used in Japan but 2-flat-pin plugs are used
instead. It is therefore advised to purchase a plug adapter beforehand.
Money : The Japanese currency is named YEN. There are coins 1, 5, 10, 50, 100 and 500 yen and notes of
1,000, 2,000, 5,000 and 10,000 yen. You can buy yen at foreign exchange banks and other authorized
money exchangers. There is no relevant differences in rates between money exchangers.
International credit cards and Travelers Checks are accepted by leading banks, hotels and stores in major
cities. However, credit card are not always convenient so obtaining some cash beforehand is
recommended.
ATMs: There are Post Office ATMs in Japan which display stickers indicating which cards are accepted.
Seven Bank ATMs are placed at 7-Eleven convenience stores and the service will be given 24 hours a day in
English, Korean, Chinese and Portuguese Guidance.
Japan has a 5% consumption tax which is levied on all goods and services purchased in Japan, including
food. In addition to the consumption tax, a 10-15% service charge is added to the bill at most hotels and
first-class restaurants.
Domestic/International Calls: Public telephones accept 10 yen and 100 yen coins and/or telephone cards.
A local call costs 10 yen per minute. If you put in two 10-yen coins and speak for less than one minute, one
of the coins will be returned to you. No change is given for partial use of a 100 yen coin. Prepaid telephone
cards cost 1,000 yen from kiosks at train stations and convenience stores. Charges for inter-city calls vary
according to the distance. A direct overseas call can be made from a public telephone displaying an
International and Domestic Telephone sign. These phones are not widespread, but can be found at airports,
hotels, and other key facilities. Direct dial calls can be made via a telephone company using the company's
access number.
Page 15

Study Tour Details
Participation Fee :
 6days – 5nights: 1,700 USD/per
Vietnamese tours having a minimum of 10 persons.
 7days – 6nights: 1,800 USD/per
※ A person can join
※ Joining together with Malaysia Group or Singapore Group,…
The fee includes :
 Hotel Accommodation for 5 nights
 Lunch and dinner for 5 days (except dinner on Wednesday)
Breakfast at the hotel
Welcome party on Sunday and farewell party on Thursday
 Arrangements for factory visits escorted by Hirayama Staff
 Transportation during the tour, including company visits and sightseeing
 Education materials and text books
 Interpreter’s fee during the training program and factory visits
 Hirayama Staff assistance and cultural technical inputs during the tour
The fee excludes :
 Travel to and from Japan (Airfare)
 Travel insurance and alcohol drinks during meals or elsewhere
 Incidentals (telephone calls, additional drinks, laundry, etc.)
Page 16

Organization
HIRAYAMA VIETNAM CO.,LTD
R703. VET Building, 98 Hoang Quoc Viet Str,
Cau Giay Dist, Hanoi, Vietnam
TEL:+84-4-3959-0247
FAX:+84-4-3959-0246
www.hirayamavietnam.com.vn
Study Tour Manager
1. Phung Thai Ha(Ms.)
Cellar phone: +84-(0)974-525-943
haptt@hirayamavietnam.com.vn
2. Dam Thu Phuong(Ms.)
Cellar phone: +84-(0)974-590-470
phuongdt@hirayamavietnam.com.vn
Mansion of Prosperity
The Japan Kaizen Tour – Contact
Please feel free to contact us for further questions.
Page 17

Khóa đào tạo TPS Kaizen Tour 2015

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Khóa đào tạo TPS Kaizen Tour 2015