Toyota Boshoku Kyushu – Factory Tour
Toyota Boshoku group operates around the globe and they are a major tier-one supplier to the Toyota Group. The Kyushu company has two plants; the Honsha (head) Plant in Kamizaki City in Saga Prefecture and the Miyata Plant located right by Toyota’s factory in Fukuoka Prefecture.
- Company: Toyota Boshoku Kyushu Corporation
- Foundation: 1991
- Location: Headquartered in Saga Prefecutre
- Main Business: Manufacturing of automotive interior products, power-train components
Toyota Boshoku Kyushu – Lean Characteristics
TPS, Just-In-Time, Karakuri, Standard Work, Visual Management
Toyota Boshoku Kyushu is a major first-tier supplier to the Toyota Group and produces seats, door trims and engine components exclusively for Lexus models manufactured by Toyota Motor Kyushu.
At the Honsha Plant, a majority of the production area is spread over two floors of the same building where over 1000 employees are purely making seats. The key processes to produce the seats involve cloth cutting, sewing, foam production, seat track assembly, welding of the frame and final seat assembly.
Being a major supplier to Toyota, the key elements of the Toyota Production System are on display including JIT delivery, kanban and standard work.
As with many factories in Japan in recent years, Toyota Boshoku Kyushu have challenged their employees to consider the zero-energy approach of karakuri to improve efficiency, ergonomics and reduce maintenance costs.
The Honsha Plant tour will also showcase excellent examples of effective visual management tools used throughout the shop floor.
I highly recommend the Lean Study Tour of Japan as an experience not to be missed. Having attended the tour for the past three years, supporting our clients, I have come away with new learnings every time. Whether you are new to Lean Thinking or well into your Lean Journey you will undoubtedly have an…
It was an excellent tour – professionally run and well executed. The companies selected implemented lean at a high degree. The passion they exhibited in sharing their lean journey was very inspiring. I have learned new strategies to bring home to implement. A time well spent.
Dear Paul, Ben and Eri, We would just like to take a moment to thank you for such a wonderful tour. You exceeded all our expectations for a week long journey – from your very professional approach and even more personal service. The week was extremely insightful, and we could not stop talking about what…
I would highly recommend the tour to anyone who is in the business of improving people. The ideas stimulated through this tour have helped me reform our entire vision of what improvement means for our business.
Amazing Tour. Great experience to see and share with Japanese managers. I learned a lot about their culture, their way to think, to work and to improve by themselves. Great moments during training and after work. Thanks a lot. We will return back home with a new eye and mindset.
I attended the Shinka Management / Ai Group / JMAC Lean Japan Study Tour in 2010 – outstanding, highly recommended. (I don’t have this much fun when I go on holiday.) To see the cultural home of Lean Manufacturing is an experience you will never forget. Ride on a bullet train, walk the factory floor…
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.