Kewpie – Factory Tour
Kewpie Corporation is a Japanese manufacturer that produces and sells condiments, salad dressing, egg products, jams and health foods. It is well known for its popular brand of mayonnaise that comes in a soft-squeeze plastic bottle with a distinctive Kewpie baby doll logo and a red cap. The company operates eight plants in Japan and has several production bases overseas including in South East Asia, Europe and the United States.
Corporate Information
- Company: Kewpie Corporation
- Foundation: 1919
- Location: Headquartered in Tokyo
- Main Business: Manufacturing of packaged food products including condiments, dressing, egg products
Kewpie Corporation – Lean Characteristics
QC Circle, High-Mix, Low-Volume Production
Kewpie Corporation is a well-known food production company with over 100 years of history. The company founder Toichiro Nakashima encountered mayonnaise during his study visit to the United States and founded the company in 1919 with a hope to create delicious and nutritious condiments for the Japanese. The company began production of Japan’s first mayonnaise product in 1925.
Kewpie now operates eight plants in Japan with a clear distinction of roles and functions among each plant. The company designates two plants as their mother factories (namely Goka plant in Ibaraki Prefecture which covers Eastern Japan and Kobe Plant in Hyogo Prefecture for Western Japan) and the remaining six are regarded as their satellite plants. At their mother plants, the company’s flagship products are manufactured in large scale. In addition, the latest production technologies and equipment are also introduced and tested before being transferred to their satellite factories. Their satellite factories are where a wide range of their food products in varying volume are manufactured in high-mix, low-volume production environments. Their production is achieved in a flexible manner with the application of factory automation systems developed over the years.
The company has set up a corporate-wide Quality Control circle program. QC circles are small groups made up of shop floor operators responsible for quality control. They voluntarily and continuously undertake activities that improve the quality of their products as well as the safety and efficiency of their operation.
Kewpie Koromo plant is a satellite plant which was established in 1958 in Toyota City, Aichi Prefecture. The visit to Koromo plant provides an insight into the effective use of high-tech tools to achieve a high level of quality and efficiency as well as good examples of their QC circle activities.
Zurich, Switzerland
It was an inspiring week with great learnings around lean and how it is applied across various levels of the supply chain. The tour also provides a nice glimpse into the Japanese culture with its amazing food and friendly people.
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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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Denver, Colorado, United States
This was my third visit to Japan with Shinka Management and it is difficult for me to find the right words to express my gratitude for such a well-organized tour and my appreciation for the high quality and on-target content. In my previous visits I received very valuable information related to continuous improvement principles and…
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Warrensburg, Missouri, United States
We learned from the masters (sensei), who were filled with wisdom, passion and experience. The Lean Japan Tour content was very practical and made a lot of sense. We received excellent hospitality from Paul and Craig of Shinka Management.
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Newcastle, New South Wales, Australia
Businesses need every weapon at their disposal to help compete in a global market. This tour opens up more ideas and opportunities and is highly recommended to manufacturers, engineering or service related industries. Everyone can learn something on this tour! Paul and Ben have done a marvelous job of putting together an action-packed week, which…
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Houston, Texas, United States
I highly recommend this tour. You will learn lean from the experts which will greatly facilitate your lean journey.
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The Shinka Management Lean Japan Tour is a professional development program run several times annually. The program, led by Shinka Management lean consultants, 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.
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 Kewpie. For Kewpie-related product, service and general public factory tour inquiries, please contact Kewpie directly.
Visiting Japan?
Prepare for your visit with the Shinka Management Guide to Japanese Business Etiquette.