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 09:00-12:00TPS Work-shop Training Session①-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. A^er 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 o^en 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 [email protected]

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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