Gifu Auto Body – Factory Tour
Gifu Auto Body is one of the 13 Toyota final assembly plants in Japan. They were established as a truck body maker in 1940 to supply military trucks for Toyota. The company today mainly produces the Toyota HiAce van and Coaster bus and consistently receives the Toyota award for quality within the group.
Corporate Information
- Company: Gifu Auto Body
- Foundation: 1940
- Location: Gifu Prefecture
- Main Business: Automotive manufacturing
Gifu Auto Body – Lean Characteristics
TPS, Jidoka, Just-In-Time Production, 5S, TPM
Gifu Auto Body is one of the 13 Toyota final assembly plants in Japan and consistently receives the Toyota award for quality within the group. Their major product is the Toyota HiAce vehicle (they also manufacture emergency vehicles based on the HiAce design), and more recently in 2017 they also started manufacturing the Toyota Coaster bus.
Gifu Auto Body refers to their system as the Good Production System (GPS), but it is nothing but an excellent example of the Toyota Production System (TPS) at work.
The Shinka Management team includes three former managers from Gifu Auto Body, including Akinori Hyodo, a former factory manager and director of the plant. The visit provides a comprehensive and operator-level view of factory operations, coupled with insights from our Japanese senior consultants based on their 30+ years experience working in the plant. There are examples of electric kanban systems, just-in-time delivery, customized equipment and poka-yoke.
Gifu Auto Body has a clever use of space throughout the plant. This has been required over the years due to the expansion of operations within building size limitations. The life of older equipment has been extended considerably through 5S and TPM programs.
I enjoyed every aspect of this extremely well organised kaizen tour including: factory visits, translations by Paul and Ben, TPS training, sightseeing, accommodation, transportation, and meals. This tour is a must for anyone trying to understand / implement LEAN into their business or organisation. I hope the tour continues for many years to come as…
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I recently had the opportunity to participate in the Lean Japan Tour by Shinka Management, and it was an exceptional experience. The tour is meticulously designed for a concise 7-day itinerary, providing deep and practical insights into Lean Manufacturing. The blend of informative sessions and real-world observations made the learning process both engaging and highly…
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It was an exciting experience learning about Japan’s culture and industrial mentality. I had the honor of seeing and experiencing the industrial culture in Japan and exploring the reasons for its prosperity based on the principle of “kaizen”, as well as witnessing the work environment in a distinctive way embodied in the principle of 5S. It was…
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I was a part of the November 2013 Lean Japan Tour and would highly recommend it for anyone who is serious about Lean Manufacturing. Ben and Paul are well organised and have put together a great tour. The tour is very enjoyable and a great insight into Lean manufacturing. I have come back with a…
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I thoroughly enjoyed the opportunity to learn the Toyota Production System from the source. I look forward to implementing the many findings in our plant. This experience has given me a different approach to improving our plant’s lean journey. Thank you again for everything.
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The Lean Japan Tour was the best lean management experience I have had. I wish I had done this earlier, so I could have done some things differently. One learns that some aspects of lean that one thought one knew, really have a different dimension to them. It helps to see lean management where it…
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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 lean and kaizen seminars, hands-on lean training and visits to several benchmark lean companies. For further information and program dates, see the lean 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.