Japan Industrial Intelligence Manufacturing Exploration Tour: From "Lean" to "Intelligent"

(7 Days 6 Nights)

【Project Background】

Japanese Culture - Creating Japan's Unique Mode of Production

The history and natural environment of Japan have created a unique culture of endurance, obedience, and a strong sense of collectivism. These cultural characteristics have also deeply influenced Japan's manufacturing culture. The most important feature is the continuous optimization of the organization, cultural construction, and training of people to solve problems in the production system. We often praise the craftsmanship of Japan, but we may not realize that craftsmanship is a manifestation of a country's industrial development. Striving for excellence in products while not forgetting to innovate boldly and designing their own characteristics is also one of the reasons why Japanese industry is so advanced.

Japan's Automation - Early Start and Reference

With the decrease of the working population and the increasing reluctance of the existing young people to enter hard factories, more and more manufacturing companies are beginning to actively use "automation" technology to solve the problem of "labor shortage". Around the application of automation on the factory front line, Japan started in the 1980s. As a close neighbor of Japan, China's manufacturing industry is also facing the same difficulties. What insights can Japan's automation bring to China? Can China and Japan carry out more cooperation in "intelligent manufacturing" including automation?

Lean Intelligence Landing in China - Helping Corporate Managers to Implement Cognitive Reengineering and Upgrade

In 2015, the country proposed a strategy for a strong manufacturing nation. The automotive industry, as one of the key breakthrough areas of China's manufacturing industry, corporate managers should seize the opportunity and meet the challenges. Lean intelligent manufacturing will land in China, and at that time, Huazhi International will help companies to create a low-carbon operation mode and achieve manufacturing upgrades. Let's go to the headquarters of lean, the industrial stronghold of Japan - Nagoya, to explore the secrets behind "Made in Japan"!

MICI's "Japan Lean Intelligent Manufacturing Study Tour" is creating the future, with places reserved, waiting foe you to explore the future together!

【Itinerary highlights】

● Dive into the Heart of Japanese Industry to Explore the Essence of Lean Intelligent Manufacturing in Japan

Nagoya, the Industrial Capital of Japan

● High-Profile Activities to Enhance the Sense of Ceremony and Participation in the Itinerary

Half summary: Digest what you have learned, reflect, output, practice and iterate.

Graduation ceremony: Summarize the gains of the trip and implement the learning outcomes.

● Three Major Courses, Four Learning Sessions, Directly Targeting the Core of Japanese Lean and the Essence of Intelligent Manufacturing

Learn the essence of the TPS theory - "Overview of TPS"

Explore new tools for corporate transformation - "Low-Cost Automation"

Discuss the path for lean intelligence to take root and flourish - "How Chinese Companies Can Introduce Lean Intelligent Manufacturing“

● Study Tour of Toyota Kaikan and Toyota's Suppliers to Unravel the Code of Japanese Lean Intelligent Manufacturing

Actual case of continuous improvement and Japanese-style dojo hands-on experience place - Kato Manufacturing

An industrial renowned enterprise with successful implementation of the TPS system - Watanabe Industry

Perfect implementation of TPS lean theory - AVEX Factory

At the forefront of Japan's intelligent manufacturing industry - Nissin Kogyo Co., Ltd.

Showcase Toyota's new technologies in various fields - Toyota Industrial Technology Memorial Museum

●Experience the Unique Culture where Japanese Tradition and Modernity are Intertwined

Experience  the Japanese lean culture, combining Nagoya's lean philosophy with modern atmosphere.

Clarify the historical context of Japan and explore the humanistic genes of the Toyota Production System.

【Itinerary arrangement】

Day1 Shanghai - Nagoya

Morning: Arrive in Nagoya, the Birthplace of Lean Manufacturing

City tour: Nagoya City, the capital of Aichi Prefecture in Japan, is the fourth most populous city in Japan and the fifth largest international trade port. It is one of the central cities of the Nagoya Metropolitan Area, one of the three major metropolitan areas in Japan, and was designated as one of the six major cities in Japan before World War II. In addition, Nagoya is also the center of commerce, industry, education, and transportation in the Chubu region of Japan.

Afternoon: Cultural Experience

Featured Attraction: Nagoya Castle

Reason for recommendation: Touch the historical context of Nagoya and explore the humanistic genes of the Toyota Production System.

Nagoya Castle was built by Tokugawa Ieyasu in 1612, damaged by the flames of World War II, and in 1959, the surviving buildings were restored. Although it no longer looks as it did in ancient times, the scale of the castle can still be seen. Coupled with the more than 2,000 cherry trees within the castle, when the flowers are in full bloom, all the buildings are covered in a sea of pink smoke, creating a moving scene. It is collectively known as the "Three Great Famous Castles of Japan" along with Osaka Castle and Kumamoto Castle.

Day2 Nagoya

Full Day: Master class

Course Theme: "Overview of TPS" Part I & II

Guest Lecturer: A comprehensive vehicle management director from Toyota

Learning Outcomes: Learn the essence of TPS theory

Course Introduction: "With a people-centric approach, TPS adheres to green development, respects employees, and continuously improves." This is the basic philosophy of TPS. By thoroughly eliminating waste, fluctuations, and rigidity, it pursues the rationality of product manufacturing and cost savings that prioritize quality, creating value for all stakeholders of the enterprise. Establishing such an efficient, high-quality, and low-cost production method is akin to building a house. How to build this house well? The foundation of thought is crucial. We will thoroughly analyze TPS to help students establish a holistic understanding of lean, build the basic framework of business operations, solidify the foundation of thought, and "pave the way" for enterprises to introduce lean production.

Day3 Nagoya

Morning: Business visit - Kato Manufacturing's New Factory

Visit Theme: In search of practical implementation methods of TPS

Kato Manufacturing is a third-tier supplier to Toyota Motor Corporation, established in July 1960, with four factories. It mainly processes automotive interior products, such as car ceilings and carpets, and is a major supplier of interior products for Toyota Cruiser cars.

Highlights: The visit will explore practical implementation methods of TPS, including software information management of the production system, synchronized operation production models, and automatic error-prevention devices, safety sensor devices, electronic automatic inspection devices, and training management for outsiders.

Afternoon: Dojo Practical Training - Kato Manufacturing Dojo for Continuous Improvement Exercises

Practical Training Process

1. The origin, application, and function of the Kanban system in the Toyota Production System.

2. Understand the interrelationship of various Kanbans through the simulation of the actual site.

3. Experience the importance of Kanban management and logistics.

4. Master the circulation method and path of Kanbans through practical application.

5. Observe and understand the types of Kanbans and their coordination.

Practical Training Outcomes: Gain firsthand experience of the essence of Lean Theory and practice.

Day4 Nagoya

Morning: Big Shot Course

Course Theme: Low-cost Automation

Guest speaker: Toyota ProductionvDepartment  Expert

Learning Outcomes: Witness the miracle of TPS in practice

Course introduction: Low-cost automation is becoming a tool for enterprise transformation and upgrading.

Amidst intensifying market competition, increasing labor costs, and rising raw material prices, more and more Chinese companies are beginning to focus on reducing staff while increasing efficiency, low investment with high returns, rapid response, and flexible production. They hope to use low-cost automation to create a low-carbon operation model, transform the way companies invest, and achieve corporate transformation and upgrading. However, for most Chinese companies, introducing low-cost manufacturing is not an easy task. This course will lead Chinese companies to observe Japanese benchmark enterprises at close range, learn the essence of automation, help corporate managers avoid misconceptions about automation, and draw on the practical experience of Japanese companies. It will plan the blueprint for the company to introduce low-cost automation, and promote the implementation and localization of the Toyota Production System in enterprises.

Afternoon: Business Investigation - Watanabe Industries

Visit Outcomes: Perfect implementation of the TPS Lean System, rapid changeover of production lines, ultra-low scrap rate of 0.004%.

Enterprise Introduction: Watanabe Industry in Japan focuses on the research and development, production, sales, and after-sales service of industrial machinery equipment. It is a second-tier supplier to Toyota, producing metal components. As these are safety parts for automobiles, there is a requirement for low-cost, high-quality production while completing multi-variety, small-batch production. On the production line, you can see textbook examples of "one-piece flow production and U-shaped production lines." Due to the long-term implementation of TPS improvements, the factory's mold changeover, one-piece flow, kanban, and in-process quality assurance are all very rigorous.

Day5 Nagoya

Morning: Business Investigation -AVEX Factory

Visit Theme: Learning the Advancement of Intelligent Manufacturing on the Foundation of Lean

Highlights: Toyota supplier, quality control, equipment inspection and maintenance, flexible application of TPM, continuous improvement results display, personnel education and training, perfect implementation of TPS theory.

Enterprise Introduction: AVEX Factory is one of the enterprises that apply TPS most deeply and flexibly, and it is also a place where TPS theory is perfectly implemented. In the AVEX Multi-Degree Factory, the equipment is decades old but operates normally because of the factory's flexible use of TPM. Continuous improvement is deeply integrated into the daily work of employees, and the improvement results of each day are displayed in a visual manner. The AVEX Factory also pays special attention to exceptions, starting daily morning meetings with a discussion of the day's exceptions. Having introduced TPS for over 40 years, AVEX Multi-Degree Factory has improved upon TPS; for example, the 5S here has become 2S + cleaning, greatly reducing the burden on employees.

Afternoon: Business investigation - Nissin Industrial Company

Visit Theme: Promotion of Digital Factory Based on TPS

Highlights: Real-time monitoring of domestic and overseas factory operations; automatic information collection for rapid problem identification; low-cost advancement of unmanned factory.

Enterprise Introduction: Nissin Industrial Company, a professional manufacturer of switches for the electrical and electronics industry and producer of precision metal parts, was established in 1973. As a Toyota supplier, the company specializes in the molding and processing of precision plastic parts, as well as mold making. In 2018, it received the National Award for Automation Companies in Japan and is considered a leader in the industry in terms of intelligent manufacturing levels.

Day6 Nagoya

Morning: Big Shot Course

Course Theme: "How Chinese Enterprises Study Lean Intelligent Manufacturing"

Instructor: TPS Promotion Expert, Business Management Consultant

Learning Outcomes: Explore the Path to the Successful Implementation of Lean and Intelligent Manufacturing

Course Introduction: Lean intelligent manufacturing is a highlight of Japanese business development and an inevitable path for Chinese enterprises. However, the introduction of lean intelligent manufacturing into Chinese companies is a systematic process that involves corporate culture, management philosophy, production processes, technological innovation, and more. Understanding lean intelligent manufacturing in depth and exploring how to implement it in one's own company is the theme of this training.

Afternoon: Business Investigation - Toyota Industrial Technology Memorial Museum 

Visit Outcomes: Dynamic demonstrations of automotive mechanical principles with hands-on operation and experience; simulation of the real process of modern automobile manufacturing; a collection of all representative models of the Toyota Group.

Enterprise Introduction: The Toyota Industrial Technology Memorial Museum, originally the abandoned factory building of Toyota Textiles and the predecessor of Toyota Motors, consists of three exhibition halls: the loom hall, the die-casting laboratory, and the automobile hall. The loom hall records the development history of Toyota looms, with dozens of pieces of equipment vividly and directly presenting the historical context of Toyota. The automobile hall not only showcases the development history of important automotive components but also displays representative models from various periods of Toyota. Here, one can grasp the basic principles of automated production, just-in-time production, and Toyota's mixed-model production line.

Day7 Nagoya - Shanghai

Back to Shanghai