Subaru – Factory Tour
Subaru Corporation (formerly known as Fuji Heavy Industries) is one of Japan’s globally renowned car manufacturers. Aside from the automotive manufacturing business, they also have an aerospace business and make aircraft and structural components which represents almost five percent of their revenue.
Corporate Information
- Company: Subaru Corporation
- Foundation: 1953
- Location: Headquartered in Tokyo
- Main Business: Automotive and aerospace manufacturing
Subaru Corporation – Lean Characteristics
Labor Effectiveness, One-Piece Flow Production
Subaru operates two final assembly plants very close to each other in Ota City in Gunma, Japan, and one in Indiana, USA. It produces over one million vehicles from these three facilities per annum with approximately 70% produced in Japan and 30% produced in the USA. Despite this, only 20 percent of their revenue was generated within Japan – meaning their export strategy is key to their success.
The tour will take us through the press, body (weld) and final assembly shops. This is an impressive plant for its labor effectiveness in final assembly (high value-add), its level of automation in the body shop, and the pure size of the press shop.
There is a one-day buffer of parts between the press shop and body shop due to the lot production method used in the press shop, but everything after that is one-piece flow production through the support of its network of component suppliers.
Sydney, New South Wales, Australia
The Shinka lean study mission of Japan offers participants an opportunity to see what is possible in undertaking world class manufacturing. The insights that are possible on tours like this can really challenge what you think are the real key success factors for implementation and enhance the chance of success in your own journey.
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Brisbane, Queensland, Australia
A high quality, professional and first-hand experience of how just-in-time and lean are mastered. Great for professional development and a genuine motivator to go further using the lean tools available. A marvelous cultural experience.
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Auckland, New Zealand
During the Lean Japan Tour I came to the realization that improving an organization is not through large capital investments alone. We were completely surrounded by examples of minor investments into small improvements that produced significant savings. The clever use of visual management techniques gave a clear understanding of the current situation and Ben who…
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Astana, Kazakhstan
I personally believe that an understanding of lean as a holistic concept combined with lean tools is necessary for all managers in any business. Shinka Management introduced us to the origins of lean production and provided a great opportunity to observe real companies where TPS principles are both implemented and being polished daily. Important parts…
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Jerome, Idaho, United States
I was very impressed with the professionalism and preparedness of the Shinka team. The support both before and during the tour was fantastic. It was the right mix of culture and personal development. There were lots of learnings I will take with me.
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Khafji, Saudi Arabia
As I have had a previous unpleasant experience with lean training, I was worried about how much I could gain from this tour. At the end of this magnificent experience I can confirm that Shinka Management has exceeded my expectations. They are so organized, dedicated, helpful and generous. The tour was based on very-well known…
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The Shinka Management Lean Japan Tour is a professional development program run several times annually. The program includes a mix of seminars on lean manufacturing, kaizen and Japanese business eqituette, together with hands-on lean training and visits to several benchmark lean companies. For further information and program dates, see the kaizen tour overview page.
Tour Inquiries
Interested in joining us in Japan? For additional information prior to registration please fill in the form provided or contact us.
The above form is for inquiries related to the Lean Japan Tour program, Shinka Management consulting and training services, and lean manufacturing software products. Shinka Management does not represent Subaru. For Subaru-related product and service inquiries, please contact Subaru directly.
Planning a Journey to Japan?
Prepare for your time in Japan with the Shinka Management Guide to Japanese Business Culture.