Tour Report | July 2023 Lean Japan Tour

The Shinka Management Lean Japan Tour is a one-week intensive lean management training program held several times annually in Japan. The program is led by one of our lean sensei out of the Toyota Group supported by our bilingual lean consultants, and is designed to provide participants with the correct understanding of the Toyota Production System theory and implementation approach.

July 2023 Lean Tour Program Overview

The July 2023 Shinka Management Lean Japan Tour was held on the 2nd through 8th of July 2023, with lean training and factory visits held in Tokyo, Inuyama and Ashikaga. The training program was attended by 16 lean professionals from Canada, Australia, Saudi Arabia, United Staes, Qatar, Chile, Germany and Lebanon.

Members of the Shinka Management team hosting the tour were Kaji Sensei (Senior Consultant, Japan), Hyodo Sensei (Senior Consultant, Japan), Ben Sparrow (Director, Australia), Eri Dennis (Consultant, Australia) and Juan Manuel Bertero (Senior Consultant, Italy).

Sunday 2nd July – Tour Briefing and Japanese Business Etiquette Seminar

We commenced the program on a warm Sunday afternoon in Tokyo, bring the participants together for the first time. Ben Sparrow led the group through a tour briefing session, and Eri Dennis ran a seminar on Japanese Business Etiquette to prepare the group for their week ahead in Japan.

Monday 3rd July – Toyota Production System Seminar and Toyota Body Seiko Site Tour

An early start this morning for our shinkansen journey from Tokyo, with Hyodo Sensei waiting to pick up our group on our arrival in Inuyama. Hyodo Sensei kick-started our classroom training at the training center with a seminar on lean leadership, sharing his thinking and views on the fundamental qualities and skills expected from leaders while drawing on the lessons from his time as factory manager and director of the Toyota HiAce plant. We then had our first TPS seminars exploring the rationale and fundamental thinking around lean manufacturing and kaizen from the viewpoint of Kaji Sensei’s experience during his career in the Toyota Group.

In the afternoon we had the opportunity to explore the inner workings of the Toyota Body Seiko Kakamigahara Factory, an impressive facility responsible for producing automotive seat tracks for an array of popular vehicle models. This includes not only the Toyota HiAce, but also models such as the RAV4, and several others. The factory, initially owned by Gifu Auto Body, was incorporated into the Toyota Body Seiko network in 2014.

Our immersive tour of the factory floor granted us an in-depth, operator-level perspective of the intricate operations carried out daily. Emphasis was placed on uncomplicated yet potent visual management tools, standard work, the utilization of Automated Guided Vehicles (AGVs), and various economical improvement concepts that have considerably boosted productivity. Despite its workforce predominantly comprising of short-term contracted labor from hiring firms, the factory has surmounted quality assurance challenges impressively. We witnessed first-hand how they’ve managed to maintain an extraordinarily low defect rate amidst these potential hurdles.

The day concluded with a shared meal back at our hotel, where some of our group took the opportunity for a hot Japanese-style bath before getting some well-deserved rest after our early start today.

Tuesday 4th July – GI Service Factory Tour and Standard Work Seminar

We continued our TPS training with Kaji Sensei, with a focus on just-in-time production and the role of kanban in the morning, and a seminar on standard work in the afternoon.

During our afternoon visit to GI Service, Director Chikamatsu showcased an impressive operation specializing in manufacturing automobile body parts. The company’s product range encompassed insulators, supports, wheel mounts, and a variety of bespoke parts tailor-made for Toyota models such as HiAce, Crown and Land Cruiser. With a team of approximately 40, half of them full-time permanent employees and the remainder comprising contractors and temporary workers, the company demonstrated an effective employee structure, with Director Chikamatsu explaining the company’s method for optimizing staff allocation according to production requirements.

GI Service operates as a satellite facility to the neighboring Gifu Auto Body plant, and uses the Toyota Production System to achieve just-in-time production and delivery to its key customer. The efficiency of this approach was apparent as it allowed the plant to precisely match production with demand, effectively maintaining a stockpile of zero finished products, a concept that was fascinating to witness first-hand.

We concluded the day in discussion over a delicious Japanese shabu-shabu dinner.

Wednesday 5th July – Suzaki Industries Factory Tour and Kanban Simulation

The focus today was on the implementation of just-in-time and jidoka.

During our visit to Suzaki Industries, an SME supplier for Gifu Auto Body, we were introduced to a facility dedicated to the manufacturing of pressed, welded, and assembled components for the automotive sector. We had the privilege of being guided around the factory by the former Chairman, and a long-time favourite of participants on the Lean Japan Tour. He shared with us the various enhancements implemented over time to retain their status as a supplier to the Toyota Group.

The tour included an explanation of the kanban system, a methodology which underpins the factory’s production workflow. We witnessed poka-yoke (error-proofing) mechanisms, underlining their commitment to maintaining high-quality standards. The demonstration of their SMED (Single-Minute Exchange of Die) efforts was also explained which served as a testament to their dedication to efficient processes. Furthermore, Mr Suzaki showcased a production cell where layout and process improvements were undertaken, facilitating a captivating and informative discussion about the effectiveness of these alterations.

One of the key highlights of the visit was Mr Suzaki sharing his story in implementing TPS to save his company and how his encounter with his TPS mentor changed him and transformed his life. His story inspired and captivated us all and highlighted the importance of the people-to-people engagements in a lean journey.

In the afternoon the team got hands-on with kanban through a kanban simulation in our training dojo, before taking time out to climb the nearby Inuyama Castle, which dates back to the 1400’s.

Thursday 6th July – Kaizen Team Challege and Toyota HiAce Factory Tour

We were put to the test this morning with a team improvement challenge in the training dojo. We were tasked to analyse and improve a spot weld process using our learnings from the week. Kaji Sensei guided the group to ensure we applied the correct thinking and steps as we worked through the kaizen process. The difference between the before and after states were significant, and we experienced a number of ah-hahs as we worked through challenge.

In the afternoon we visited Gifu Auto Body, one of the 14 final assembly plants of Toyota in Japan, responsible for manufacture of the Toyota HiAce van and Toyota Coaster bus. The factory prides itself on its dedication to 5S, and consistently receives the award for quality within the Toyota group. Here we completed our journey through the Toyota supply chain, having visited first and second tier suppliers earlier in the week.

The operational methodology at Gifu Auto Body, referred to as the Good Production System (GPS), was observed as an exemplar of the Toyota Production System (TPS) in action. We were shown instances of an advanced electric kanban system, Just-In-Time delivery, specialized equipment, and error-proofing (poka-yoke) procedures. Notably, Gifu Auto Body has ingeniously utilized space throughout the plant, a necessity borne from the expansion of operations within existing building constraints. Moreover, through the effective implementation of 5S and Total Productive Maintenance (TPM) programs, they have significantly prolonged the life of older equipment, demonstrating a clear commitment to efficiency and sustainability.

In the late afternoon we farewelled Kaji Sensei, Hyodo Sensei and Inuyama, and boarded a bullet train for our return to Tokyo.

Friday 7th July – Ashikaga 5S Town

Today we ventured out to Ashikaga City, Tochigi Prefecture, where we learned about the impactful 5S activities that have been revitalizing the Ashikaga community since 2003. The city, known as the “5S Town,” has been conducting the 5S World Summit since 2012, with more than 200 organizations across diverse sectors such as manufacturing, tourism, and education having implemented the Ashikaga-style 5S so far.

We were joined by Mr. Hiroya Suzuki, a staunch advocate and expert on this philosophy, for a seminar on Ashikaga-style 5S. It was intriguing to learn how their approach, although not directly stemming from the Toyota Production System (TPS), effectively drives company and organizational improvement through its unique approach to kaizen.

The first company tour for the day was held at Kikuchi Gear, a participant in the Ashikaga 5S Program. With about 160 employees distributed across their head office and six factories, the company produces quality gears for a range of sectors including aerospace, automotive, construction machinery, and printing. It was enlightening to observe how their flexible production facilities met the demands of wide-ranging customer needs. Kikuchi Gear’s emphasis on 5S Kaizen as a means to foster a resilient and stronger organization capable of consistently generating profit was inspiring.

Our afternoon tour took us to Fukai, a producer of pressed and welded automotive components for brands such as Subaru, Nissan, and Mitsubishi Motors. Established in 1938 as a supplier for Nakajima Aircraft Industries (now known as Subaru), Fukai demonstrated a strong commitment to their Fukai-style 5S program. This initiative is woven into their integrated functions of R&D, die/jig design, and manufacturing (press, weld, assembly). As members of the Ashikaga 5S School network and maintaining their own 5S Committee, Fukai conducts a robust, year-round 5S program that effectively delivers tangible outcomes to improve the organization. During the shop floor tour, a representative from each department explained and demonstrated the 5S Kaizen activities they conducted to improve their operations. Throughout the tour, all Fukai employees welcomed the tour groups with warm Japanese hospitality and courteous greetings.

We were joined during the day by a journalist from the local Shimotsuke Newspaper, with an article on our visit being included in the print version of the newspaper the following morning.

During our return to Tokyo we discussed plans for implementation of our learnings on our return home, and held our farewell dinner in the evening.

Saturday 8th July – Tokyo Sightseeing and Farewell

Our final morning together was dedicated to recovery and seeing the sights in Tokyo. We commenced our sightseeing in Asakusa, with a visit to the ancient Buddhist temple Senso-ji – often regarded as one of the most significant and oldest temples in Tokyo. The iconic landmark is famous for the large red lantern hanging at the Kaminarimon or “Thunder Gate”, which serves as the main entrance to the temple.

We then traded the old for the new, with a visit to glitzy Ginza, before heading back to start farewelling those departing for their flights.

We look forward to sharing stories of how each of us have implemented our learnings from the week.

Participant Feedback

Thank you to the group for providing the following feedback on their experience on the July 2023 Lean Japan Tour.

Join us in Japan!

The Lean Japan Tour is run several times annually as an open-registration program, hosting participants from various countries. Positions are made available on a first-come first-served basis.

Shinka Management also makes the Lean Japan Tour available to companies wishing to send a large group of staff on a dedicated program. The timing, length, content and delivery language of these programs can be customised.

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Visit the Lean Japan Tour page to learn more about the program, view the full list of future program dates, or request further information via the form below.