Lean Japan Tour

The Lean Japan Tour is a training program designed to provide participants with a comprehensive understanding of the Toyota Production System and an immersive experience in lean manufacturing and kaizen practices at some of Japan’s top companies.

Lean manufacturing study missions are ideal for company owners, leaders, managers and lean practitioners who want to learn lean manufacturing practices directly from the source in Japan, with the intention of implementing these practices back home. Programs are led by Shinka Management directors and senior consultants fluent in Japanese and experienced with lean manufacturing implementation.

Participants on lean insight tours gain firsthand experience in lean and kaizen, build valuable business insights, and interact with senior management at world-class lean companies. Further, lean insight tours to Japan are an opportunity to build relationships with fellow participants from around the globe.

Our Japan study missions typically last for one week, with visits to multiple lean companies and participation in lean training seminars. Programs normally commence on Sunday afternoon with a briefing session held at our hotel, and conclude on Saturday with an optional relaxed sightseeing day.

In addition to classroom and hands-on training activities, we typically visit the genba of around five lean/TPS focused organisations during our week-long kaizen tours. We endeavour to include automotive and manufacturing sites that have strong examples of TPS application, and depending on the tour program also include lean healthcare, government and service-related organizations from time-to-time.

Availability of companies for inclusion on the Lean Japan Tour is subject to host company operational requirements that can vary seasonally. Participants are notified of the companies to be visited usually one month in advance of program commencement. Examples of companies that we have visited in the past are provided on this page.

The Lean Japan Tour program includes a strong emphasis on Toyota’s production methods, frequently featuring visits to facilities such as Gifu Auto Body, an excellent example of a Toyota final assembly plant. Currently, however, access to Gifu Auto Body is restricted.

As our tours prioritize delivering the highest-quality learning experiences in lean management, we carefully select site visits that best support our educational objectives. While we have access to other Toyota final assembly plants, we may choose alternative automotive or non-automotive factories that offer superior and more relevant learning opportunities.

Every Lean Japan Tour program integrates extensive training and seminars led by former Toyota managers, alongside visits to leading Toyota suppliers recognized for their strong application of the Toyota Production System.

We understand many participants have a specific interest in visiting a Toyota final assembly plant; however, our tours focus on meaningful, in-depth learning rather than industrial tourism. Therefore, a Toyota plant visit, while possible, is not guaranteed for our open-registration Lean Japan Tour programs. For dedicated or customized Lean Japan Tours or Japan study missions with a specific requirement for visiting a Toyota final assembly plant, we generally can accommodate this, subject to timing and factory operational constraints.

The tour includes hands-on lean training sessions, kaizen workshops, and seminars on topics such as the Toyota Production System and Just-In-Time production. The training is structured such that participants new to lean manufacturing will be provided with a comprehensive understanding of the theory to enable them to gain the most from the factory visits, whilst experienced lean practitioners will have the opportunity to learn directly from former Toyota managers regarding implementation practices of TPS in Japan. Workbooks are provided which include all content covered.

Yes. Although not the focus of the Lean Japan Tour, participants will enjoy various cultural experiences, such as Japanese cuisine and visits to local landmarks, alongside their professional development activities. The Shinka Management team takes great pride in being able to showcase the best that Japan has to offer – from both industrial engineering and culture perspectives.

Once you are ready to make a tour booking, please fill out our Lean Japan Tour Registration Form and email it back to our office. Please read our Travel Terms and Conditions carefully before you make a booking.

We will send you an invoice once your tour registration form is processed. Tour registrations are accepted once payment has been confirmed, on a first come, first served basis. As the number of our tour participants is limited to a maximum of 20 participants per program, please process the payment promptly to avoid any disappointment.

Included in the price of our open-registration Lean Japan Tour programs are accommodation for six nights, meals (with the exception of two free evenings, and Saturday lunch), tour-related domestic transport, lean factory tours and site visits, kaizen and lean seminars, discussions, sightseeing and interpreters covering the dates of the tour.

Not included in the price of the tour are airfares to and from Japan, airport transfers, travel insurance and personal expenses (including hotel mini-bar, laundry, etc.), and any extra accommodation outside the official tour schedule.

If you plan on arriving in Japan a day or more before the tour and/or staying on after the tour, and require additional hotel booking(s) in the same accommodation the tour group is staying, please let us know as soon as possible.

Standard Cancellation & Change Policy (1–4 participants)

The following applies to individual bookings, small groups, or where fewer than five participants from the same organization are cancelling or changing:

• More than 28 days before tour commencement: No fee.

• 28–14 days before tour commencement: US$500 fee per participant.

• Within 14 days of tour commencement: US$1,500 fee per participant.

Participant substitutions within the same company are permitted at no additional cost.

Large-Scale Group Changes (5 or more participants from the same organization)

Where five or more participants from the same organization cancel or change their booking, the following policy applies to those participants:

• More than 45 days before tour commencement: No fee.

• 45–28 days before tour commencement: US$1,500 fee per participant.

• Within 14 days of tour commencement: US$3,000 fee per participant.

For the purpose of this policy, cancellations or changes made by participants from the same organization will be assessed in aggregate, including those made at different times prior to tour commencement.

If the total number of participants cancelling or changing reaches five or more, the Large-Scale Group Changes policy will apply to all affected participants.

A tour confirmation email will be sent to you as soon as your tour is determined to run or at least 45 days prior to the tour commencement, whichever comes first. Please note that Shinka Management reserves the right to alter the tour dates up to 45 days prior to tour commencement. For this reason, we ask participants to refrain from purchasing their airfare or travel insurance until 45 days prior to tour commencement unless given earlier clearance. If you wish to book your flight tickets before the tour confirmation, please ensure you purchase with flexibility or a reasonable cancellation policy.

Participants holding a passport from the countries listed on the following link may not be required to apply for a visa prior to travel to Japan and may be granted landing permission for short-term stays (up to 90 days) for such purposes as business trips (i.e. this tour) and sightseeing without obtaining a visa.

Ministry of Foreign Affairs of Japan – Exemption of Visa

If you hold a passport from another country, please contact your local Japanese Embassy or Consulate for details. Shinka Management is unable to provide direct assistance and is not authorised to give any specific visa-related advice.

If you require a visa to enter Japan, Shinka Management can issue an invitation letter and supporting documents for your visa application. Please contact us as soon as possible if you will need an invitation letter in order to obtain a Japan entry visa. Your tour fee must be paid in full before the invitation letter is issued to you.

The invitation letter and supporting documents will be supplied to you in electronic format. Currently the majority of Japanese diplomatic missions accept documents in electronic format. If you are required to submit the original copy of the documents, they can be sent to you by post. Please note that there is a postage and handling fee applicable when original documents must be sent internationally. Please inform us no later than one month prior to your planned departure date so that the original copy can be delivered to you in time for your visa application.

It is your responsibility to determine whether a visa is required for you to enter Japan. When a visa is required, please be sure to make necessary arrangements by yourself before your departure. The issuance of the invitation letter does not guarantee that you will be granted an entry permit to Japan.

If you have any visa related questions or concerns, please refer to the website below and contact your nearest Japanese Embassy or Consulate for further information. Shinka Management is unable to provide any specific visa-related advice, and is unable to provide direct support for your visa application.

Ministry of Foreign Affairs of Japan – VISA

Shinka Management reserves the right to alter the Lean Japan Tour program dates up to 45 days prior to tour commencement. We ask that our tour participants refrain from purchasing their airfare or travel insurance until 45 days prior to tour commencement unless given earlier clearance. Generally, we do give earlier clearance to allow for flights to be booked at good rates. This is just a precaution as we take no responsibility for the refund of airfares or travel insurance. If you wish to book your flight tickets before the tour confirmation, please ensure you purchase with flexibility or a reasonable cancellation policy.

Yes. Shinka Management requests you to hold an adequate travel insurance for the duration of your trip. Travel insurance is not included in the price of the tour. It is a requirement that all participants are covered by an appropriate travel insurance policy. Shinka Management accepts no liability for any loss or damages or expenses of any kind.

Airport transfers are not included in the price of a lean tour program and participants are expected to make their own way to a designated tour hotel upon arrival in Japan. There are various convenient, easy and inexpensive self-guided train and bus transfer options from Tokyo’s Narita and Haneda airports to our hotel in Tokyo, and written guidance is provided to tour participants regarding these options. If you wish to book an airport meet-and-assist staff to be present at the airport to help you with your airport transfer upon your arrival, please let us know so we can provide you with the details of our recommended service provider.

Yes. Please let us know as soon as possible if you are likely to require extra night(s) of accommodation outside of the dates of one of our lean insight tours. The cost of the extra accommodation is to be borne by the participant and paid directly at the hotel.

Yes, we can usually accommodate allergy-related dietary requirements for meals included in our Japan study tours, provided we are notified well in advance of the tour start date. We also make efforts to accommodate vegetarian preferences; however, again, early notification is essential to allow our hosts time to prepare accordingly.

We are pleased to have hosted many Muslim clients on our Lean Japan Tour over the years.

For open-registration Lean Japan Tours, we can provide meals without alcohol and pork if notified well ahead of time. However, Halal-certified meals are generally not available for open-registration tours, as Halal-certified restaurants are limited in Japan.

Due to the structured schedule of our open-registration programs, which include classroom sessions, factory visits, and travel arrangements, time is not specifically allocated for prayer breaks.

For custom tours designed for individual companies, we have greater flexibility in adjusting the schedule to incorporate Halal-certified meal options (where available) and a Zuhr prayer break.

Shinka Management has welcomed participants from over 70 countries on our study missions in Japan, and we aim to be inclusive of participants from all backgrounds, regardless of geopolitical issues. However, we are sometimes legally required to decline registrations for government or military organizations, companies, or individuals sanctioned under Japanese or Australian law, or restricted from entering Japan. This decision is determined by government regulations and host organizations. Additionally, we expect all participants to show respect toward fellow participants, regardless of any geopolitical tensions.

We reserve the right to decline applications from individuals or organizations that may not align with the educational objectives of our Japan-based programs.

Casual business attire will be more than appropriate. Ties are not necessary. Long-sleeved shirts, long pants and enclosed shoes will be required for most factory visits, but you may wish to pack short-sleeved shirts, such as corporate shirts or polos, for other days. Slip-on business shoes can be convenient around Japan as there is the regular need to take them off. For the same reason, it is also a good idea to pack a few pair of clean socks (without any holes)! Steel-cap safety shoes are not required at any of the facilities that we visit.

Irrespective of the season of your travel in Japan, it is recommended that you pack a fold-up umbrella.

Shinka Management will provide necessary PPE for factory visits such as safety glasses, helmet and hearing protection where required. Participants are not required to bring safety shoes (e.g. steel-capped shoes). However, please ensure to bring flat enclosed shoes with you together with long-sleeved shirts (or jacket) and long pants for factory visits.

Japan runs on AC 100 volts. Please check your electronic devices prior to your departure to ensure that they will operate in Japan without the need for a transformer. On the power adapter or power pack of your appliance, you should find “Input” or “AC”. If this says 100-240V, you should have no problem. Many power adapters and power packs for appliances such as laptop computers, mobile phones, cameras and electric shavers have 100-240V capability.

The only extra item you will require is a plug adapter for a Japanese power point. Adapters for Type A sockets are available in most electronic stores, department stores, travel stores and at the airport, however it is recommended to purchase one prior to departure. Please don’t purchase adapters with an extra earth plug as these will not fit into the wall socket.

Please bring some spending money to cover airport transfers, two evening meals and Saturday lunch, as well as for your personal spending, laundry, souvenirs etc.

Credit cards are widely accepted in major cities and larger stores, however there are still many smaller shops in Japan where only cash is accepted. Credit cards cannot be used with most ATMs to withdraw cash, however most convenience store ATMs do accept foreign credit cards and EFTPOS cards for this purpose. These ATMs have English and other language prompts. In Japan it is always best to be prepared with cash in case the banking system lets you down.

In order to avoid having your credit card frozen, it is recommended to contact your bank prior to departure to advise that you will be travelling overseas.

Certain requirements and rules apply when bringing medicines into Japan depending on the type and amount of medicines. The medications and prescription drugs that can be brought into Japan are subject to control under the Pharmaceutical Affairs Law and the Customs Law of Japan. This may mean that some common medications and over-the-counter drugs in your country may be illegal in Japan.

If you wish to bring any medicines for personal use into Japan and have any questions or concerns, please refer to the website of Japan’s Ministry of Health, Labour, and Welfare (MHLW) and contact the relevant medical authorities in Japan.

We strongly encourage all participants to keep their calendars clear during the Lean Japan Tour and to avoid scheduling work commitments during the program. The tour is designed as an intensive learning experience, with factory visits, seminars, discussions, travel, and networking opportunities scheduled throughout the week.

We recommend advising your company in advance that you will be fully engaged in the program and may have limited availability for meetings and other work-related activities. While unforeseen circumstances can arise, participants should plan to attend all scheduled activities to gain the maximum benefit from the tour.

Yes. We are happy to work with your company to create a lean/kaizen tour program in Japan to cater for your staff. Generally, we suggest group sizes of between 15 and 20 participants for this option. Please contact us to discuss your requirements.

Yes. Our open-registration Lean Japan Tour programs are run several times annually in English, and from time-to-time in Spanish. We have experience running customised Lean Japan Tour and TPS insight programs in Vietnamese and Russian, and are happy to cater for other languages should the need arise. Please contact us to discuss your requirements.