The Japan Kaizen Tour - Giappone-Italia

HIRAYAMA Consulting 

The Japan Kaizen Tour 

Mansion 

October 14th – 20th, 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 Motor Background 

� Seminars and Kaizen Training 

� Case Examples 

� Factory Tours 

� 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 

14th Sun 

Day 2 

15th Mon 

Plant Tour Nissan Motors 

Study Topic 

�Arrive in Narita 

Airport 

�Transfer to Hotel 

Day 3 

16 th Tue 

Day 4 

17 th Wed 

Day 5 

18 th Thu 

Day 6 

19 th Fri 

Lunch 

� If time allows, 

short sightseeing 

in Tokyo 

Lunch Lunch Lunch Lunch Lunch 

Plant Tour 

Study Topic 

Day 7 

20 th 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 

� Schedule subjected to change 

HIRAYAMA - The Japan Kaizen Tour Schedule 

October 14th – 20th , 2012 

TPS Dojo 

Workshop 1 

Basic concept of 

TPS, 

Standard Work, 

Detect waste 

TPS Dojo 

Workshop 2 

Kaizen 

Technique by 

Motion analysis 

Toyota Motor 

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)

Some Details about Plant Visits 

The Kaizen Japan Study Tour – Company Profile 

2 nd Day - Monday 

Nissan Motor Co., Ltd. 

Established in Yokohama City, Kanagawa Prefecture, Nissan currently manufactures vehicles in 20 countries and areas 

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

Date of Establishment : December 26, 1933 

Number of Employees : 155,099 (consolidated basis) 

Web URL : http://www.nissan-global.com/EN/ 

Yokohama Plant (Engines, Motors and Suspensions) 

The Yokohama Plant is the site where Nissan Motor Co., Ltd. was founded in 1933. The plant began operations 

in 1935 as the first integrated, automobile mass-production facility in Japan. Made up of three areas divided by 

function, the Yokohama Plant is Nissan’s main component plant for the manufacture of engines, motors and 

suspensions. A comprehensive quality assurance system has been put in place to supply products of even higher 

quality. This includes the installation of an in-line motoring test bench (MTB) and durability testing shop. 

Area: Approx. 537,000 m2 

Employees: Approx. 3,400 (as of April 1, 2011) 

Production volume: Approx. 534,000 engines/year 

Models produced: Engines, Engine parts, Motor assembly for EV and HEV, 

Suspension parts, Forgings, Aluminum castings, Welded parts, Stampings, 

and Catalytic converter parts 

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 well known as member of the HITACHI Group, producing magnetos for aircraft domestically 

since 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 in 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 

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

11:15-12:00 Q&A Session 

13:00-16:00 Seminar by Mr. Terasaki 

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 


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 

Kokusandenki 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 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 


The Japan Kaizen Tour – Company Profiles 

3rd Day - Tuesday 

HIRAYAMA Training Center – TPS Dojo- 

Through this course you 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. 

 

09:30-10:00 Company Introduction 

10:00-11:00 Plant Tour 

11:00-11:30 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 



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 persues 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 Masks, 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, Sockets, Sensors, Batteries 

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


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 

Consultant : Hiromitsu HAYASHIDA 

・ 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. 


The Japan Kaizen Tour – Costs & More Information 

Dates 

Oct 14 th – 20 th , 2012 

• Participants need to arrive at the Hotel in Japan on the afternoon of October 14 th , 2012ndin order to be 

fully prepared for the week’s study mission. On the return trip, participants will depart from Japan on the 

following Saturday. 

Participation Fee 

Yen 500,000 per person 

* Full payment due date is September 28th, 2012 

The fee includes : 

� Accommodation for seven nights with breakfast , Lunch & dinner 

� Factory visits 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 : September 21 st , 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 

Study Tour Managers: Miyuki Honda miyuky-honda@hirayamastaff.co.jp 

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 

www.genbakaizen.com 

Study Tour Manager 

Miyuky Honda and Noboru Takeuchi 

noboru-takeuchi2@hirayamastaff.co.jp 

The Japan Kaizen Tour – Contact 

Mansion of Prosperity 

In cooperation with: 

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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