Are you interested in visiting some of the best factories of the best lean manufacturing companies in the world? Then join me on the Japan Kaikaku Experience the last week of October, presented by Gemba Research. Gemba has been doing these trips for several years and has the experience and inside contacts to do it best.
We build relationships with companies in Japan who we believe are world leaders in kaizen. These companies have been doing kaizen in some form for between 5 and 50 years. Each company has an active Suggestion System whereby employees suggest and implement 1 to 3 ideas per month, per person.
Each company faces unique challenges and has adapted Toyota Production System (TPS) principles faithfully but flexibly. It is a sign of their commitment to Lean thinking that they are willing to show us the best of what they have done, believing that by sharing their knowledge they will themselves be challenged to rise to the next level.
What types of things will we see and learn?
The companies we visit have integrated the management philosophies with day to day execution of improvement activity. The results that they have generated over the years are dramatic. As an example, Toku Manufacturing is able to run nearly 300 machines with 35 people, all because of the advanced level of Jidoka (Low Cost Intelligent Automation) that they have achieved.
What companies will we visit? Some examples:
We typically visit two or more Toyota sites depending on availability and areas of interest of our study mission group. We visit at least one assembly plant in order to see one-piece flow assembly paced to Takt Time, kanbans, Andon boards, Just in Time delivery of materials, pokayoke, Standard Work, and other TPS principles. We also visit an engine manufacturing facility to see Jidoka, TPM, Standard Work, and excellent examples of 5S and visual management.
Denso is a leading global supplier of advanced technology, systems and components. Worldwide, the company employs 87,000 people in 31 countries. They have been a long-term partner of Toyota in developing both automobile technologies as well as Lean systems (namely kanban). Today Denso is continuously improving their operations and you will see excellent examples of kanban, one-piece flow cell, 5S, visual management, Standard Work, Jidoka, and other TPS principles in action.
At Toyota Home, you will see TPS in action in a high mix, low volume environment. The work content from one unit to the next varies tremendously, yet each unit flows at Takt Time. The 'show room factory' is an example of good 5S and visual management. You will get an up-close look at how to make large, complex products flow one at a time.
I've decided to go on this once-in-a-lifetime type of trip and hope you will too. For more information visit the Japan Kaikaku Experience at Gemba Research.