The Japan Kaizen Tour - Giappone-Italia

HIRAYAMA Consulting 

The Japan Kaizen Tour 

in cooperation with MAEMA sas 

Mansion 

25 th Nov – 1 st Dec, 2012 

Copyright (C) 2012 HIRAYAMA Co., Ltd. All Rights Reserved. URL http://www.genbakaizen.com

HIRAYAMA – The Japan Kaizen Tour 

Why Does "The Japan Kaizen Tour" Work for You? 

The Toyota Production System is considered to be the final production control method, which has led Toyota Motors to be the 

most competitive motor company in the world. Every company in the world today is interested in whether to implement the 

Toyota Production System to their system. We organized, "The Japan Kaizen Tour", to see the current status of its place of birth, 

at Toyota Motors. We offer seminars, on-site Kaizen training, and what's more, a factory tour at the world-leading facility for 

structure and management of the Toyota Production System. 

Characteristics of "The Japan Kaizen Tour" 

� Training by Consultants with a Toyota Motors Background 

� Seminars and Kaizen Training 

� Case Examples 

� A Factory Tour 

� Small-Group Tours of under 20 Participants to Lead to Substantial Output 

Objectives of "The Japan Kaizen Tour" 

� To Study the Background and Structure of Toyota Production System 

� To Analyze and Solve any Problems Participant's May have Together 

� To Have a Tour of The World's Highest Level Factory 

� To Learn About Japanese Culture and the Background of the Toyota Production System 

� To Allow for Communication Between Fellow Seminar Members 


Breakfast 

Day 1 

25 th ,Sun 

Day 2 

26 th , Mon 

Plant Tour Nissan Motors 

Study Topic 

�Arrive in Narita 

Airport 

�Transfer to Hotel 

Day 3 

27 th ,Tue 

Day 4 

28 th , Wed 

Day 5 

29 th ,Thu 

Day 6 

30 th ,Fri 

Lunch 

� If time allows, 

short sightseeing 

in Tokyo 

Lunch Lunch Lunch Lunch Lunch 

Plant Tour 

Study Topic 

HIRAYAMA - The Japan Kaizen Tour Schedule 

25th November – 1 st December, 2012 

Day 7 

1 st , Sat 

Breakfast Breakfast Breakfast Breakfast Breakfast Breakfast 

Assembly Plant 

N. 2 car 

manufacturer in 

Japan 

Kokusan Denki, 

and discussion 

with Mr. Terasaki 

former vice 

president 

Hitachi group 

Successfully 

introduced TPS 

system 

TPS Dojo 

Workshop 1 

Basic concept of 

TPS, 

Standard Work, 

Detect waste 

TPS Dojo 

Workshop 2 

Kaizen 

Technique by 

Motion analysis 

� Schedule subjected to change 

Toyota Motors 

Assembly plant, 

Center of TPS – 

JIT, Jidoka 

Avex 

Leading 

manufacturer 

for automatic 

transmission 

Discussion with 

Former Toyota 

Executive 

Q & A 

Debriefing 

Tokai Shinei 

Electronics 

5S, Kaizen activity 

And Visual 

management 

Copyright (C) 2012 HIRAYAMA Co.,Ltd. All Rights Reserved. URL http://www.genbakaizen.com 

OMRON Kyoto 

Kaizen activities, 5S, 

Unique production 

system 

Sightseeing 

(Kyoto) 

�Depart from 

Kansai Airport 

(Osaka)

The Kaizen Japan Study Tour – Company Profile 

2nd Day - Monday 

Nissan Motors Co., Ltd. 

Established in Yokohama City, Kanagawa Pref., Nissan Motor Co., Ltd. currently manufactures vehicles in 2 

0 countries and areas around the world and offers products and services in more than 160 countries and 

areas worldwide. 

Oppama Plant 

The Oppama Plant is one of Nissan’s major vehicle manufacturing plants in Japan. As a leader in 

automated manufacturing, the plant started producing “Nissan LEAF” in 2010, the first mass-producible 

electric vehicle in the same lines with the other vehicles. The Global Training Center of Oppama 

develops human resources for Nissan’s worldwide plants, and the Oppama Proving Ground conducts test 

drives and other evaluation activities. Oppama Wharf is a major shipping center capable of transporting 

some 80,000 vehicles per month, both from Oppama and other Nissan plants. 

Area: Approx. 1,707,000 m2 

Employees: Approx. 2,700 (as of April 1, 2011) 

Production capacity: Approx. 430,000 units/year 

Models produced: Nissan LEAF, Juke, Cube, Note, Tiida, 

Tiida Latio, Bluebird Sylphy 

Copyright (C) 2012 HIRAYAMA Co.,Ltd. All Rights Reserved. URL http://www.genbakaizen.com

Kokusan Denki Co., Ltd. 

The Japan Kaizen Detailed Schedule 

2nd Day - Monday 

Kokusan Denki is known as HITACHI Group, producing magnetos for aircraft domestically in 1931. 

Taking advantages of applied technologies of electromagnetic and production technologies that have been 

developed since its establishment, Kokusan Denki has always led the industries while aggressively entering into 

such fields as various engine electric appliances, small-size and high-precision electric motors. 

Its products are being used by customers of various fields, including motorcycles, automobiles, 

outboard motors, agricultural machinery, ATM (automated teller machine) and etc. 

 

14:00-15:00 Introduction of the company + explanation of Kaizen activities 

15:00-15:45 Production line tour 

w/ HIRAYAMA Consultant – Mr. Terasaki (Ex-President of Kokusan Denki) 

15:45-16:30 Q&A Session 

Date of Establishment : 10 July, 1931 

Number of Employees : 710 employees 

Products : Engine Ignition Systems, Electric Motors, Alternators & Welders 

Web URL : http://www.kokusandenki.co.jp 

Copyright (C) 2012 HIRAYAMA Co.,Ltd. All Rights Reserved. URL http://www.genbakaizen.com

Consultant : Akashi TERASAKI 

Hitachi, Ltd. 

Company Position Experience 

Kokusan Denki, Ltd. 

(Electric Appliances 

for Motorcycle & 

Multipurpose Engine, 

Motor, 

Generator) 

India Nippon Electricals, 

Ltd. 

[INE] 

(Joint Corporation with 

Kokusan Denki in India) 

The Japan Kaizen Tour - Consultant Profiles 

Senior Manager of Prototype Mfg. 

Dpt. 

Senior Manager of Production 

Engineering Dpt. 

Chief Manager of KAIZEN 

Promotion Center 

Managing Director & 

Senior Manager 

Chief Manager of KAIZEN 

Promotion Center 

Director 

・ Assumption of Chief Manager of KAIZEN Promotion Center in 1991 

・ Promoted the Improvement Activity in Automotive Products Division in 

Hitachi 

・ Received the Grand Prix Award of Improvement consecutive 3 years 

from 1993 to 1995 

・ [Result of JIT Activity for 3 years] 

Productivity 194% Up Manpower Reducing 37% Down 

Space Reducing 40% Down Defect Reducing 52% Down 

Inventory Reducing 16% Down Lead Time 71% Down 

Changeover Time 37% Down Time of Facilities 42% Down 

・ Transferred to Kokusan Denki, Ltd., subsidiary company of 

Hitachi, in 1995 

・ Directed the “Actual KAIZEN Improvement Activity” in Kokusan 

Denki 

・ Prepared to make the 100% of Hitachi Improvement Know How 

・ And started “Terasaki Way Improvement” 

・ Assumption of Director of INE in 1991 

・ Directed the “Actual Improvement Activity” at 5 companies of INE 

group 

・ Received the Grand Prix Award of Improvement in 1997 and the 

result of improvement was in the spotlight in the world 

Kokusan Denki , Ltd. President ・ Directed the “Actual KAIZEN Improvement 


The Japan Kaizen Tour – Company Profiles 

3rd Day - Tuesday 

HIRAYAMA Training Center – TPS Dojo- 

This course will 

① acquire the ability as managers & supervisors to execute Kaizen by yourself 

② acquire TPS fundamental knowledge 

③ execute Genchi, Genbutsu principle and see actual work site of skills to detect MUDA, MURA and MURI 

④ experience and master Kaizen technique by executing motion analysis using the model production line. 

 

09:00-10:00 Introduction of TPS and Kaizen in Toyota way 

10:15-11:30 Explanation of Standard work sheet & Combination chart 

11:30-12:30 Finding problems from radiator assembly line 

12:30-13:40 Lunch 

14:00-15:30 Detection of MUDA, MURA, MURI and group discussion 

15:40-16:30 Rebuilding and implementation of the line 

16:40-17:30 Q&A Session 

Web URL : http://www.genbakaizen.com 


The Kaizen Japan Study Tour – Company Profile 

4th Day - Wednesday 

TOYOTA Motor Corporation 

Toyota Motor Corporation, Japan`s #1 carmaker creates cars, pickups, minivans, and SUVs which include 

such models as Camry, Corolla, 4Runner, Land Cruiser, Sienna, the luxury Lexus line, the Scion brand, 

and the hybrid brand. Toyota sells its vehicles in more than 170 countries and regions worldwide. 

Toyota`s primary markets for its automobiles are Japan, North America, Europe and Asia. 

Toyota also makes forklifts and manufactured housing, and offers consumer financial services. 

They have a driving ambition to become greener. The company makes a hybrid-powered (gas & electric) 

sedan-the Prius- that is being snapped up in US and European markets. 

The company recorded revenues of $244 billion during the fiscal year of 2011, a decrease of 3.7% over 2011. 

and sales profit $3.6 Billion, a decrease of 42% over previous year. 

 

9:00-10:10 Toyota Assembly plant 

10:10-11:30 Transfer to the exhibition center 

10:30-11:30 Toyota Kaikan Exhibition Center 

11:45-12:30 Lunch at Restaurant “Socio” in Toyota Kaikan 

Date of Establishment : August, 1937 

Number of Employees : 69,478 employees 

Products : Automobile, Housing, Finance/Banking, etc. 

Web URL : http://www.toyota.co.jp 


AVEX 

Under the motto: “The development of a company starts with the development of human resources,” 

AVEX trains engineers who can machine and grind components on a micron scale. 

Their high skills enable AVEX to operate an integrated system to produce everything from prototypes 

to mass-produced products. 

In fiscal 2006, AVEX was selected as one of the “A Selection of 300 of Japan's Monozukuri 

(Manufacturing) SMEs”. 

Hydraulic control valves for automotive automatic transmission systems require extremely high precision 

to ensure their accurate sliding movement in the systems. The valve outer diameter tolerance must be 

within just +/-0.0008 mm. The smooth acceleration and deceleration of automatic cars depends on 

our technologies embodied in these valves that are almost the same size as a finger. 

 

14:00-14:45 Company Introduction 

14:45-15:45 Plant Tour 

15:45-16:30 Q&A 

The Japan Kaizen Detailed Schedule 

4 th Day - Wednesday 

Date of Establishment : June, 1953 

Number of Employees : 140 employees 

Products : Automotive Parts (A/T valves, Breaks, Engine Parts, etc.) 

Web URL : http://www.avex-inc.co.jp 


Consultant : Hiromitsu HAYASHIDA 

Company Position Experience 

Toyota Motor Corporation 

Production Engineer 

Factory Manager 

Gifu Auto Body Co., Ltd Board Director 

Toyota Motor Corporation 

The Japan Kaizen Tour - Consultant Profiles 

・ Practical level experience of welding process at 

・ process planning, equipment planning, and equipment 

・ design, etc. for car body. 

・ Supervisory activities in the production department 

・ of the welding process. 

・ Participated in internal training courses for the 

・ Toyota Production System and participated in practice 

・ and instructed for various Kaizen activities. 

・ Supervised and managed as Director in Charge of 

・ Production Engineering, Production Control, and 

・ Production Department, etc. 

・ Practiced and supervised various Kaizen activities 

・ based on the Toyota Production System. 

・ Planning operation for the new production assembly 

Production Engineering Director 

・ line for passenger cars. 

Director 

Factory Deputy 

General Manager 

・ Supervisory operation in the Production Department 

・ of the passenger car assembly line. 

・ Overall management of plant operation. 



5 th day, Thursday 

Tokai Shinei Electronics Industrial Co., Ltd. 

Gemba Kaizen examples by the effective cleaning power -5S is the principle of the successive company. 

Mr. Tanaka, president of the company sincerely promote three basics, “Exchange greetings”, “Clean 

surroundings” and “Place shoes neatly side by side” which are the foundation of human resource 

cultivation. Company also pursues participative management through visible information system 

to all the employees. 

 

10:00-10:45 Introduction of the company + Lecture by Mr. Tanaka, president of TSK 

10:45-11:30 Production line tour 

11:30-12:00 Discussion, Q & A 

Date of Establishment : July 1, 1969 

Number of Employees : 120 employees (Consolidated base: 250 emp.) 

Products : Designing & Manufacturing of Printed Wiring Board, Single-sided PWB 

without plate TH. Multilayer PWB, Metal Mask, etc. 

Web URL : http://www.tsk-pcb.co.jp 



6th day - Friday 

OMRON Kyoto Taiyo 

Omron Kyoto Taiyo with a partnership with Japan Sun Industries have promoted job opportunities 

for the disabled under the motto of `No Charity, But a Chance`, by creating supportive working 

environment in which the disabled are able to create more chances for socially satisfying lives. 

The main philosophy is to derive the underlying potential of the disable and maximizing their 

capability by providing mechanical aids including unique supportive jigs and kaizen improvement 

in their working environment. 

Sample 

9:00- 9:40 Introduction of the company and Low Cost Automation 

9:45-10:45 Plant tour of Sockets & Sensor 

11:00-11:30 Q&A Session 

Date of Establishment : 1985 

Number of Employees : 19 employees + Handicapped workers 

Products : Switches, Socket, Sensor, Battery 

Web URL : http://www.kyoto-taiyo.omron.co.jp 


TPS Study Tour – Kyoto Information 

Kyoto, “Japan’s heartland”, is a city that over a period of 1000 years, dating from the decision to move the capital to Kyoto in 794, 

nurtured a unique kind of culture and came to be considered the mother of culture and Japan’s foremost travel destination. 

Kyoto was the capital of Japan and the Emperor’s place of residence till the capital was shifted to Tokyo in 1868. Kyoto is a 

breathtaking city that offers historical sites, beautiful nature scenes and friendly locals. 

Population: 1,473,746 inhabitants 

Economy: Information Technology (Nintendo, Omrom, Kyocera), 

Tourism and handcrafts 

Access: 73 minutes from Kansai Airport by JR "Haruka" Kansai Airport Limited Express 

2 h and 22 min from Tokyo Station (Bullet Train) 

Climate: November in Kyoto is end of autumn and little bit cold. temperatures is around 

5”C to 20”C . Enjoy autumn leaves which turned to red & yellow over the mountain. 

Clothing: Sweater, over coat to keep you comfortable. No-tie required for plant visit and 

also during training program. 

Tourist Spots: the all city is a touristic spot with dozens of temples and historical sites. 

Here are some of them: Kyoto Tower , Kiyomizu-dera Temple, Nijo Castle, Kinkakuji Temple , 

Gion Town, Tetsugaku no michi. 

Food: Kyoto has its own culinary culture. Located far from the ocean, it was difficult to 

get fresh seafood. That's why in the Kyo-ryori (Kyoto cousin) they use dry food, 

vegetables and soya bean products. To savor and enjoy these ingredients, various 

cooking methods and techniques were invented and in Japanese traditional 

restaurants, it became the height of sophistication, creating delicious dishes that 

show the seasonal beauty of nature on a plate almost like a work of art. 


TPS Study Tour – Other basic Info 

Electricity: The voltage used throughout Japan is uniformly 100 volts, A.C. There are two kinds of 

frequencies in use; 50 Hertz in eastern Japan and 60 Hertz in western Japan (including Nagoya, Kyoto and 

Osaka). There are no columnar-shaped plugs or 3-pin plugs used in Japan but 2-flat-pin plugs are used 

instead. It is therefore advised to purchase a plug adapter beforehand. 

Domestic/International Calls: Public telephones accept 10 yen and 100 yen coins and/or telephone cards. 

A local call costs 10 yen per minute. If you put in two 10-yen coins and speak for less than one minute, one 

of the coins will be returned to you. No change is given for partial use of a 100 yen coin. Prepaid telephone 

cards cost 1,000 yen from kiosks at train stations and convenience stores. Charges for inter-city calls vary 

according to the distance. A direct overseas call can be made from a public telephone displaying an 

International and Domestic Telephone sign. These phones are not widespread, but can be found at airports, 

hotels, and other key facilities. Direct dial calls can be made via a telephone company using the company's 

access number. 

Money : The Japanese currency is named YEN. There are coins 1, 5, 10, 50, 100 and 500 yen and notes of 

1,000, 2,000, 5,000 and 10,000 yen. You can buy yen at foreign exchange banks and other authorized 

money exchangers. There is no relevant differences in rates between money exchangers. 

International credit cards and Travelers Checks are accepted by leading banks, hotels and stores in major 

cities. However, credit card are not always convenient so obtaining some cash beforehand is 

recommended. 

ATMs: There are Post Office ATMs in Japan which display stickers indicating which cards are accepted. 

Seven Bank ATMs are placed at 7-Eleven convenience stores and the service will be given 24 hours a day in 

English, Korean, Chinese and Portuguese Guidance. 

Japan has a 5% consumption tax which is levied on all goods and services purchased in Japan, including 

food. In addition to the consumption tax, a 10-15% service charge is added to the bill at most hotels and 

first-class restaurants. 


The Japan Kaizen Tour – Costs & More Information 

Dates 

25 th Novn – 1 st Dec , 2012 

• Participants need to arrive in Japan on the afternoon of November 25th, 2012ndin order to be fully 

prepared for the weeks study mission. On the return trip, participants will depart Japan on the following 

Saturday. 

Participation Fee 

Japanese yen 500,000 per person 

•Full payment due date is October 25th, 2012 

The fee includes : 

� Accommodation for six nights with breakfast , Lunch & 2 times dinners 

� Factory visit and work-shop training by ex-Toyota trainers 

� Transportation during the tour includes factory visit escorted by Hirayama staff 

� Seminar materials and text books 

� Interpreter fee during training program & factory visit 

� Sightseeing in Kyoto 

The fee excludes : 

• Travel to and from Japan (Airfare) 

• Transportation from/to airport to/from hotel (Limousine bus service available) 

• Travel insurance 

• Incidentals (telephone calls, alcoholic drinks during meals, laundry, etc.) 

Cancellation Policy 

• No charge before registration – The registration due date : November 12 th , 2012 


Registration 

Name(s) and title : 

# of Participants : Company(s) : 

Address : City : State : 

Postal Code : Country : 

Phone : Fax : Email : 

Flight Schedule : Arrival Time Departure Time(Date) 

For Application: 

Maema S.a.s. di Manisera & C. 

Via Verrocchio 154 - 25124 Brescia – Italy 

Tel/Fax ++39 030 2305952 - Mob. 335 6748968 - E-mail: maema@giappone-italia.it 

Application and full payment (to Hirayama bank account): one month before departure 

--------------- 

Organization 

HIRAYAMA Consulting - Shinagawa Place 6F, 1-8-40 Konan, Minato-ku, Tokyo 108-0075 Japan 

Phone +81-3-5783-3571 - Fax: +81-3-3548-1445 

Manager Noboru Takeuchi - E-mail: noboru-takeuchi2@hirayamastaff.co.jp 

Copyright (C) 2012 HIRAYAMA Co.,Ltd. All Rights Reserved.

Organization 

HIRAYAMA Consulting 

Shinagawa Place 6F 

1-8-40 Konan, Minato-ku 

Tokyo 108-0075 Japan 

TEL:+81-3-5783-3571 

FAX:+81-3-5783-3572 

Mobile ph.: +81-80-5688-7950 

www.genbakaizen.com 

Study Tour Manager 

Noboru Takeuchi 

noboru-takeuchi2@hirayamastaff.co.jp 

---------- 

Miyuky Honda 

miyuky-honda@hirayamastaff.co.jp 

The KARAKURI Fair & TPS Study Mission – Contact 

Mansion of Prosperity 

Maema S.a.s. di Manisera & C. 

Via Verrocchio 154 - 25124 Brescia – Italy 

Tel/Fax ++39 030 2305952 - Mob. 335 6748968 - E-mail: maema@giappone-italia.it 

Please feel free to contact us for further questions.

The Japan Kaizen Tour - Giappone-Italia

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