The Kaizen Japan Study Tour - Giappone-Italia

HIRAYAMA Consulting in cooperation with MAEMA Sas 

Kaizen Japan Study Tour 

Mansion 

April 15 – 22, 2012 

Copyright (C) 2011 HIRAYAMA Co.,Ltd. All Rights Reserved. URL http://www.genbakaizen.com

The Kaizen Japan Study Tour 

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

While not only Europe but many regions around the world are suffering because of the severe and well-known financial and 

economic crisis, it is important to act for the recovery and future growth of the companies’ business. In Japan, after many 

years of sluggish expansion and natural disasters, many companies are actually increasing their competitiveness in the 

manufacturing field even in comparison with the low cost labor countries. TPS (Toyota Production System) led Kaizen in quality, 

productivity, cost and time reduction, environment friendly technologies… are improving company profits and image. That is 

why we think that a study and training tour, visiting some process and assembly industry plants of these 

Japaneseorganizations could help western companies to get some hints and lessons to learn. 

Characteristics of "The Kaizen Japan Study Tour" 

� Education and Assistance by Experts and Consultants with TPM and TPS Background 

� Seminars and Kaizen Training by ex Toyota Motor Managers and Trainers 

� Case Examples 

� Factory visits 

� Small-Group Tour to Lead Participants to Substantial Output 

Objectives of "The Kaizen Japan Study Tour" 

� To Study the Background and Structure of Toyota Production System and Other Japanese Methodologies 

� To Share, Analyze and Solve Together Problems Participants May Have 

�To Have a Tour to The World's Highest Level Factories 

�To Learn about Japanese Culture and the Background of its Excellent Production Systems 


Breakfast 

Plant Tour 

Study Topic 

Day 1 

15th Sun 

�Arrive at Kansai 

International 

Airport (Osaka) 

�Transfer to Hotel 

� Tour Orientation 

& Dinner 

Day 2 

16th Mon 

Plant Tour �Free time 

Horiba Ltd. 

Day 3 

17 th Tue 

Day 4 

18th Wed 

Day 5 

19th Thu 

Day 6 

20th, Fri 

Day 7 & 8 

21 st— 22 nd Sat-Sun 

Breakfast Breakfast Breakfast Breakfast Breakfast Breakfast 

Sightseeing in 

Kyoto 

Study culture & 

heart of Japan 

TPS Dojo 

Work-shop 

Training 1 

Standard work in 

TPS, Just in ttime 

Toyota Motor Daido steel Kokusan Denki 

Assembly plant, 

Center of TPS 

Optimal use of 

employees’ 

capabilities 

Pursuit of 

advanced 

technologies 

Hitachi group 

Successfully 

introduced TPS 

system 

Lunch Lunch Lunch Lunch Lunch Lunch 

Every day 

Q&A 

Session - 

Dinner 

The Kaizen Japan Study Tour Schedule 

April 15 – 22 , 2012 

Leader of 

automotive 

emission 

measurement 

systems 

Tokai Shinei 

Electronics 

5S activity, Visual 

Management, 

Kaizen activities 

TPS Dojo 

Work-shop 

training 2 

Kaizen Technique 

by Motion analysis 

Nippon Steel Corp. 

No 1. Steel 

company 

� Schedule subjected to slight changes 

Copyright (C) 2011 HIRAYAMA Co.,Ltd. All Rights Reserved. URL http://www.genbakaizen.com 

Lecture, Discussion 

Q & A by 

Mr.Terasaki 

Former vice 

president of 

Kokusan Denki 

Sat. 21 

Sightseeing 

Hakone 

National park 

--- 

Tokyo & 

Shopping 

---- 

Dinner 

Sun. 22 

�Departure 

from Narita 

International 

Airport

Some Details about Plant Visits 

Horiba Co., Ltd. 

The Kaizen Japan Study Tour – Company Profile 

2 nd day - Monday 

HORIBA is a global group of companies that provides analytical and measurement 

equipments in fields that are indispensable to people’s lives, including environment, 

health, safety, and energy. HORIBA products hold No.1 or No.2 share positions in the global 

markets – for example, automotive emission measurement systems command an 80% 

share of the global market – accounting for approximately 60% of total sales. 

Prior to 2005 company’s growth was led by the Automotive Test Systems segment. 

In the subsequent five years, the company has been supported by the recovery and growth of 

the Semiconductor Instruments & Systems segment. Over the next five years, leading up to 

2015, company expects attractive profit contributions from the Medical Diagnostic Instruments 

& Systems segment. 

Date of Establishment : June, 1953 

Number of Employees : 5,202 employees (as of Dec, 2010) 

Sales Turnover: 119 Billion Yen (Dec, 2010) 

Net profit: 7.9 Billion Yen 

Products : Automotive test systems, Process & environmental, Medical diagnostics, 

Semiconductor, Scientific instruments , etc. 

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



3rd & 4 th Day – Tuesday/Wednesday 

HIRAYAMA Training Center – TPS Dojo- 

Through this course you will 

① acquire the ability ,as manager & supervisor, 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 

 

Tuesday 

9:00-10:30 Introduction of TPS and Kaizen in Toyota way 

10:40-11:20 Explanation of standard work sheet & combination chart 

11:20-12:00 Finding problems from radiator assembly line 

Wednesday 

13:00-14:00 Detection of MUDA, MURA, MURI and group discussion 

14:15-15:30 Discussion 

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

16:30-17:00 Summary, Q & A session 

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



3rd day, Tuesday 

Tokai Shinei Electronics Industrial Co., Ltd. 

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

Mr. Tanaka, president of the company sincerely promotes three basic principles: “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. 

 

14:00-15:15 Introduction of the company + Lecture by Mr. Tanaka, president of TSK 

15:20-16:20 Production line tour 

16:30-17:00 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 

Copyright (C) 2011 HIRAYAMA Co., Ltd. All Rights Reserved. URL http://www.genbakaizen.com


4th Day - Wednesday 

TOYOTA Motor Corporation 

Toyota Motor Corporation, Japan`s N°1 carmaker, manufactures 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 billions during the fiscal year of 2011, a decrease of 3.7% over 2010, 

and sales profit $3.6 billions, a decrease of 42% over the 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 


Daido Steel Co., Ltd. 

The company is developing the steel for the practical mechanical structure centering on the co-development 

with automobile manufacturers for the purpose of promoting the manufacturer of the high function 

automobile parts. The company is also developing the materials with new functions by combination of 

manufacturing technologies of alloy designing, heat treatment and so on. 

Founded: August 19, 1916 

Incorporated: February 1, 1950 

Net Sales (consolidated basis) : 472,062 billion yen (FY2011). 298,769 billion Yen (non-consolidated) 

Number of Employees (consolidate basis): 10,272 employees, 3,239 (non-consolidated basis) 

Products in the Steel business: Automotive parts, industrial machinery parts, electrical machinery parts, 

welding, Electric and magnetic materials, Die forging , precise hot forging and others. 

Head office: Higashi-ku, Nagoya, Aichi Pref. 

 

Chita plant: Tokai city, Aichi pref. 

Hoshizaki plant: Minami-ku, Nagoya, Aichi pref. 

Shibukawa plant: Shibukawa city, Gunma pref. 

Web URL : www.daido.co.jp/e/ 


5th Day - Thursday 


Nippon Steel Corp. 


5th Day - Thursday 

The history of the Nippon Steel Group goes back to 1857 when in Kamaishi, Nippon Steel successfully tapped 

steel from Japan’s first western style blast furnace. 

Nippon Steel Corporation was established in 1970 when Yawata Steel and Fuji Steel merged together. Its main 

business activities are related to Steelmaking, Engineering & Construction, Urban Development, Chemicals, 

New Materials, System Solutions. Its Head Office is located in Tokyo; its net sales are 4,109,774 million yen 

(Consolidated, FY2011); its employees are 16,150 (March 31, 2011). 

Nagoya Works 

The Nagoya Works is the only general base in the Chubu district that can meet a variety of needs. 

At the Nagoya Works, Nippon Steel Corp. has a setup that enables the company to offer a wide range of products 

including various steel sheets of thicknesses from 0.05 mm, which is thinner than paper, to 900 mm, and also 

seam-welded pipes. 

Date of Establishment : Established in September 1958 (as Tokai Iron & Steel Co., Ltd.) 

Number of Employees : 2,836 

Site Area: 6,230,000 m² 

Crude steel production: 6,281,000 tons (FY 2007) 

Web URL : http://www.nsc.co.jp/en/index.html 


Kokusan Denki Co., Ltd. 


6th Day - Friday 

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. 

 

9:30-10:15 Introduction of the company + explanation of Kaizen activities 

10:15-11:15 Production line tour 

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

11:15-12:00 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 


Hitachi, Ltd. 

Company Position Experience 

Kokusan Denki, Ltd. 

(Electric Appliances 

for Motorcycle & 

Multipurpose Engine, 

Motor, 

Generator) 

India Nippon Electricals, 

Ltd. 

[INE] 

(Joint Corporation with 

Kokusandenki in India) 

The Kaizen Japan Study Tour – Lecture Consultant Profile 

Consultant : Akashi TERASAKI 

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 Down Time of Facilities 42% Down 

・ Transferred to Kokusandenki, Ltd., subsidiary company of 

Hitachi, in 1995 

・ Directed the “Actual KAIZEN Improvement Activity” in 

Kokusandenki 

・ 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 Dennki , Ltd. President ・ Directed the “Actual KAIZEN Improvement “ 


Tour Details 

Dates – One whole week, from April 15 to April 22 

The participants will arrive at the Kansai Airport (Osaka) on Sunday. If they arrive in the morning as group, they will 

go to the Hotel by Hirayama coach, have lunch, visit some interesting spots, and attend the Tour introduction and 

evening dinner. On the return trip, participants will depart from Narita Airport (Tokyo) on Sunday. It is possible to 

add some extra days before or after the Tour, for personal reasons. Hirayama staff will help from the logistic 

standpoint but the expenses will be paid personally. 

Participation Fee (To pay one month before the tour starting) 

The fee includes : 

� Hotel Accommodation for 7 nights, included Internet access 

� 7 breakfasts, 7 lunches, 7 dinners 

� Arrangements for factory visits escorted by Hirayama Staff 

� Transportation during the tour, including company visits and sightseeing 

� Education materials and text books 

� Interpreter’s fee during the training program and factory visits 

� Hirayama Staff assistance and cultural technical inputs during the tour 

The fee excludes : 

• Travel to and from Japan (Airfare) 

• Transportation to and from the airport in Japan (if not in the same group) 

• Travel insurance and alcohol drinks during meals or elsewhere 

• Incidentals (telephone calls, additional drinks, laundry, etc.) 

Cancellation Policy 

• 15 days prior to the starting date of the tour No charge 

• 7 – 14 days prior to the starting date of the tour 30% of the tour fare 

• 6 – 3 days prior to the starting date of the tour 50% of the tour fare 

• 2 days prior to the starting date of the tour 100% of the tour fare 

Copyright (C) 2011 HIRAYAMA Co.,Ltd. All Rights Reserved.

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) 2011 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 

www.genbakaizen.com 

Study Tour Manager 

Noboru Takeuchi 

noboru-takeuchi2@hirayamastaff.co.jp 

----------- 

The Kaizen Japan Study Tour – 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 Kaizen Japan Study Tour - Giappone-Italia

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?