Japan Kaizen Study Mission Nov2016-Incl Toyota Tour

The
Japan Kaizen
Study Mission
Unique experience at
World-Class Lean
Companies
including TOYOTA tour
6th 12th November 2016
The Kaizen Japan Study Tour

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 Japanese organizations could help the 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
JAPAN
MALAYSIA
Expitris Worldwide Sdn Bhd
http://genbakaizen.com
60-1, Block H Platinum Walk, Jalan Langkawi, Setapak 53300

Kuala Lumpur Malaysia
Tel: ++603 4143 5560 Fax: ++603 4143 5563
info@expitris.com, ww.expitris.com

Schedule
7 days, 6 nights 6th 12th November 2016
Day
Day 0
(Sun)
Day 1
(Mon)
Day 2
(Tue)
Time
Program
PM Arrival at Nagoya Airport (6th Nov16)
Check-in Hotel
TPS Work-shop Training Session
AM
Lecture & Hands-on Training by ex-Toyota trainers
PM
AM
PM
Day 3
(Wed)
AM
PM
Day 4
(Thu)
Day 5
(Fri)
Day 6
(Sat)
AM
PM
TPS Work-shop Training Session

Detect waste & Kaizen method by ex-Toyota trainers
Toyota Motor Co. Plant Visit
Origin of TPS: Kanban, Andon , Poka Yoke, etc
Toyota Techno Museum - Site Visit
History of Toyota and TPS
Plant/Company Visit Selection 1
Kaizen System, Employee Management
Fabric Automation
Employee Motivation, Unique Systems
Discussion Session Japanese Lecturer
Q&A session on TPS
AM
Plant Visit Selection 4

Improvements Ideas
PM
Japan Culture
Shopping and sightseeing in Kyoto Areas
AM
Departure from Osaka International Airport

(on 12th Nov16)
JAPAN
MALAYSIA

Tel: ++603 4143 5560 Fax: ++603 4143 5563

Day 1 - Monday Workshop Training
TPS DOJO Hirayama Training Center

The Hirayama Training center originally started from giving basic TPS operation training to
employees assigned to work at Toyota Motors or group companies, and have been making
remarkable output. Activities of the training center evolved and currently the main purpose l
ies in spreading TPS Kaizen method domestically and globally, supporting educational and
training programs. Until present, more the 3,000 participants from 30 countries had attende
d our Dojo.
Mr.
Mr. S. Minegishi
Mr.
Mr. M. Fujii
Mr.
Mr. T. Ishigaki
In this course we will:

1) acquire the ability as managers & supervisors to execute Kaizen by yourself
2) acquire TPS fundamental knowledge
3) apply Genchi, Genbutsu principle to detect MUDA, MURA and MURI
4) experience and master Kaizen technique by motion analysis.
<Schedule>
09:00 - 10:30 Explanation of Standard work sheet & Combination chart
10:45 - 12:00 Standard work sheet & Combination chart practice
12:00 - 13:00 Lunch
13:00 - 14:30 Finding problems from radiator assembly line
14:40 - 16:50 Detection of MUDA, MURA, MURI and group discussion
17:10 - 17:30 Discussion
JAPAN
MALAYSIA

Tel: ++603 4143 5560 Fax: ++603 4143 5563

Day 1 - Monday Workshop Training
Improve your skill and technique by

our well equipped training facilities and
vastly experienced staffs.
Learn philosophy of lean

management and manufacturing,
TPS principles and Genba
Kaizen (Continuous improvement
in work place)
Improve yourself learning and

analyzing your movement through
installed model line and standard
operational combination list
JAPAN
MALAYSIA

Tel: ++603 4143 5560 Fax: ++603 4143 5563
The Kaizen Japan Study Tour Example

Day 2 - Tuesday Company Visit
TOYOTA Motor Corporation

Toyota Motor Corporation, Japan`s #1 carmaker creates cars, pickups, minivans, and SUVs which include
such models as Yaris, Prius and the luxury Lexus line. Toyota sells its vehicles in more than 170 countries
and regions worldwide. In 2012, the company reported the production of its 200-millionth vehicle, being th
e world's first automobile manufacturer to produce more than 10 million vehicles per year. In 2013, Toyota
was the worlds best selling manufacturer for 2013 with 9.98 million vehicles sold. .
Toyota Motor Corporation's production system is a way of "making things" that is sometimes referred to as
a "lean manufacturing system" or a "Just-in-Time (JIT) system," and has come to be well known and studi
ed worldwide.
Date of Establishment : August, 1937
Number of Employees : 333,498 employees
Products : Automobile, Housing, Finance/Banking, etc.
Web URL : http://www.toyota.co.jp
<Tour Schedule>
10:30-11:00 Toyota Kaikan Exhibition Center
11:00-12:45 Plant Visit
12:45-13:00
Transfer to the exhibition center
13:00-14:00 Lunch at Restaurant Socio in Toyota Kaikan
Day 2 - Tuesday Site visit
TOYOTA Techno Museum

The Museum was founded in a cooperation of 13 companies of Toyota Group, and uses the location and
buildings of Toyota Bousekis main office, the origin place of TOYOTA. The museum's mission is to
systematically introduce the history of Japanese manufacturing technology to those who will be
responsible for its future development and the evolving world of automobile engineering.
<Visit Schedule 15:00-17:00>
Summary of the exhibition facilities:
1. Textile Machinery Pavilion Spinning and Weaving Technology
2. Automobile Pavilion Automobile Technology and Industry
Automobile Mechanisms and Component Parts, development of
automobile and production technology
Material laboratory, prototyping plant
Address: 4-1-35, Noritake Shinmachi, Nishi-Ku, Nagoya City
Web URL: http://www.tcmit.org
JAPAN
MALAYSIA

Tel: ++603 4143 5560 Fax: ++603 4143 5563
The Kaizen Japan Study Tour Example

Day 3 - Wednesday Plant visit
Mitsubishi Electric Corporation
The Mitsubishi Electric Group operates on the corporate principle of contributing to creating a vibrant and affluent
society by enhancing its technologies, services, and creative powers, as a leader in the manufacture and sales of
electric and electronic equipment used in energy and electric systems, industrial automation, information and
communication systems, electronic devices, and home appliances.
Mitsubishi Electric Corporations Nagoya Plant is the companys principal facility for automation equipment
production, ensuring supplies of key parts to Mitsubishi Electrics factory automation lines worldwide.
Production of: heavy electric machinery systems, industrial mechatronics, information and telecommunications
systems, electronic devices, manufacturing and sales of home electric appliances, etc.
Mitsubishi Electric Group
Founded: January , 1921
Employees: 117,314 (Group total), 1,970 (Nagoya works)
Annual turnover: 3,639.4 billion Yen
(USD 44.4 Billion in a rate of 1USD= 82 JPY)
URL: http://www.mitsubishielectric.co.jp/
Day 3 - Wednesday Plant visit

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.
Since 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.
<Tour Schedule>
14:00-14:30 Company Introduction
14:30-15:30 Plant Tour
15:30-16:00 Q&A
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
JAPAN
MALAYSIA

Tel: ++603 4143 5560 Fax: ++603 4143 5563

Day 4 - Thursday Company Visit
HAYASHIDA, Hiromitsu
Career profile: Toyota Motor Corporation, Horie Metal Co., Ltd.

HAYASHIDA was Manufacturing Manager and Deputy General Manager at
Tahara Plant while at Toyota Motor Corporation. He then held a position of
Director at Gifu Body Industry Co., Ltd and of Executive Director at Horie Metal
Co., Ltd. A TPS specialist. His expertise lies with welding and assembly
technology. He promotes Kaizen (continuous improvement) that
comprehensively encompasses entire factory operations including procurement
and production control. He is well-versed in giving advice to different types of
factories and plants.
Day 4 - Thursday Discussion Session
Mirai Industry
The company is an electric installation equipment manufacturer and well-known as unique management
by CEO Akio Yamada. More than 10, 000 kaizen improvement) ideas per year submitted from employees
and very popular for employee welfare policy, mandatory retirement at the age of 70, no layoff, 140
holidays a year, overseas travel for all employees every 5 years, no night overtime, 3 years maternity
leave, 10 days off at the year-end holidays and highest salary in the local area. Mirai has a heaven-like
working environment for employees.
Overview of the Company
Name
Founded
Capital
Consolidated Net Sales:
Employees:
Business lines
URL:
Mirai Industry Co., Ltd.

August, 1965
\7,068 Million
\21,900 Million
780 employees
Electrical equipment materials, Plumbing
sanitary materials, water supply
& drainage and gas equipment, etc
http://mirai.co.jp
JAPAN
MALAYSIA

Tel: ++603 4143 5560 Fax: ++603 4143 5563

Day 5 - Friday Company Visit
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.
<Tour Schedule>
09:30-10:15 Introduction of the company and Low Cost Automation
10:15-11:15 Plant tour of Sockets & Sensor
11:15-11:30 Q&A Session
Date of Establishment : 1985
Products : Switches, Socket, Sensor, Battery
Web URL : http://www.kyoto-taiyo.omron.co.jp
Day 5 - Friday Japan Culture
Kiyomizu-dera
Located in the eastern part of Kyoto City, Kiyomizu-dera
is a historic temple that was established in 778, even
before Kyoto became the capital of Japan. Since its
foundation, the temple has burned down many times.
Most of the current buildings were rebuilt by the third
Shogun Tokugawa Iemitsu in the early Edo period (1631
to 1633).
The Main Hall (Hondo) of the temple is designated as a national treasure. In 1994, it was registered on the
UNESCO World Cultural Heritage List as one of the Historic Monuments of Ancient Kyoto. The two most
famous places of the temple are the Main Hall, where the Eleven Headed and Thousand Armed Kannon
Bodhisattva - which is famous for the power of answering prayers - is enshrined and Kiyomizu Stage,
which is the veranda of the Main Hall extended over a precipice.
Kiyomizu-dera (the temple of clear water) was named after Otowa Waterfall. Water from a spring in the
mountain has been falling there since its foundation. Fifteen colorfully-painted halls and pagodas stand in
its verdant precincts.
JAPAN
MALAYSIA

Tel: ++603 4143 5560 Fax: ++603 4143 5563

City Information - NAGOYA
Nagoya City, located at the center of Japan, is capital of Aichi Prefecture in Chubu Region and one of the
three major metropolitan regions (Tokyo, Osaka, and Nagoya).
Greater Nagoya, centralized in Nagoya City, is the hub of Japanese manufacturing industries, producing
over 40% of major manufacturing categories such as automobiles, automobile parts, machine tools and
aircraft parts, and exerts its role as a strong leader in the Japanese economy.
Population:
Economy:
2,263,907 inhabitants
Greater Nagoya GDP459 billion USD) Is placed 18th
comparing with the world's countries.
Tourist Spots: Nagoya Station Area (business area and modern buildings) , Nagoya Castle Area
(government and public offices ) , Sakae Area (Shopping, fashion and night life), Shirakabe (the most
powerful Shogun family Tokugawa origin)
Food: Nagoya is famous for its miso sauce cuisine and tebasaki .
Famous plates are kishimen noodle, miso-katsu cutlet,
and tebasaki fried chicken wingtips.
City Information - KYOTO

Kyoto, Japans 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 Japans foremost travel destination. Kyoto was the capital of Japan and the Emperors 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:
Economy:
1,473,746 inhabitants
Information Technology
(Nintendo, Omrom, Kyocera),
Tourism and handcrafts
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. 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.
JAPAN
MALAYSIA

Tel: ++603 4143 5560 Fax: ++603 4143 5563

Useful Information
Luggage: Recommended to pack lightly traveling around Japan. Most trains
do not provide space for bulky luggage. Overhead shelves on shinkansen
trains are about 40cm high and 60cm deep and cannot accommodate large
items. Furthermore, on many shinkansen trains the leg room is large enough
to place a suitcase in front of you, although this may not be the most
comfortable solution.
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 8% consumption tax which is levied on all goods and services
purchased in Japan, including food. In addition to the consumption tax, a 1015% service charge is added to the bill at most hotels and first-class
restaurants.
JAPAN
MALAYSIA

Tel: ++603 4143 5560 Fax: ++603 4143 5563
Study Tour Details and Registration

Dates 7 days , 6 nights
(6th 12th November 2016)

2016)
The participants must arrive at the Nagoya Airport on Sunday Afternoon to be lead to Hotel by
Hirayama Staff. In the Sunday Night will be held a Tour introduction and evening dinner. On the return
trip, participants will depart from Osaka International Airport on Saturday.
Group Fee: 3 and Above

RM18,800/- Register Before 25
Participation Fee :
Normal Price:RM23,900/Register Before 27th Sept16:
Sept16: RM21,800/Register Before 25th Aug16
Aug16:
16: RM19,800/PARTICIPANTS NAME
DESIGNATION
th
AUG16
Note: 6% GST is NOT included

PARTICIPANTS BUSSINESS email ADDRESS
*TO BOOK YOUR SEAT,YOU WILL ONLY NEED TO EMAIL OR FAX THE LAST PAGE of THIS BROCHURE (JULIAN)
Organization: __________________________________________________________________________
No need to write if same as CO stamp
Postal Address: _________________________________________________________________________

Approval: (This Booking form is invalid without signature, HR or top level management can sign it) Sign and Stamp Here
Name:_______________________________Position:_____________________
Date:______________ Person-in-charge (PIC) __________________________
Tel____________________________ Email: _____________________________
The fee includes :

Hotel Accommodation for 6 nights (breakfast and lunch included also Welcome and Farewell diner)

Travel to and from Japan, (depart Kuala Lumpur - NAGOYA, return OSAKA - Kuala Lumpur)

Arrangements for factory visits escorted by Hirayama Staff Japan

Transportation during the tour, including company visits and sightseeing

Education materials and text books

Interpreters fee during the training program and factory visits

Hirayama Staff assistance and cultural technical inputs during the tour
The fee excludes :

Transportation, from your destination to your city Airport (in Japan only if it is not in the same group)

Travel insurance, Incidentals (telephone calls, additional drinks, laundry, etc.)

All ticket, hotel, transportation or any other related expenses of any member of family brought by any participant should
be bore by the participant. No member of family is allowed to joying the tour group during Nagoya and Osaka trip.
Payment Policy :
The payment must receive within 7 days of the invoice date or 14 days after booking
Cancellation Policy :

45 days prior to the starting date of the tour
No charge

29 16 days prior to the starting date of the tour 30% of the tour fare

15 8 days prior to the starting date of the tour 50% of the tour fare

7 days prior to the starting date of the tour
100% of the tour fare
*If the event is cancelled/postponed the Organizer will refund back the money, 100%, if the payment is settled.
JAPAN
MALAYSIA

Tel: ++603 4143 5560 Fax: ++603 4143 5563

Japan Kaizen Study Mission Nov2016-Incl Toyota Tour

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The

The Kaizen Japan Study Tour

Characteristics of "The Kaizen Japan Study Tour"

Objectives of "The Kaizen Japan Study Tour"

60-1, Block H Platinum Walk, Jalan Langkawi, Setapak 53300

The Kaizen Japan Study Tour

TPS Work-shop Training Session

Plant Visit Selection 4

Departure from Osaka International Airport

60-1, Block H Platinum Walk, Jalan Langkawi, Setapak 53300

The Kaizen Japan Study Tour

TPS DOJO Hirayama Training Center

In this course we will:

60-1, Block H Platinum Walk, Jalan Langkawi, Setapak 53300

The Kaizen Japan Study Tour

Improve your skill and technique by

Learn philosophy of lean

Improve yourself learning and

60-1, Block H Platinum Walk, Jalan Langkawi, Setapak 53300

The Kaizen Japan Study Tour Example

TOYOTA Motor Corporation

Day 2 - Tuesday Site visit

TOYOTA Techno Museum

60-1, Block H Platinum Walk, Jalan Langkawi, Setapak 53300

The Kaizen Japan Study Tour Example

Day 3 - Wednesday Plant visit

60-1, Block H Platinum Walk, Jalan Langkawi, Setapak 53300

The Kaizen Japan Study Tour

Career profile: Toyota Motor Corporation, Horie Metal Co., Ltd.

Day 4 - Thursday Discussion Session

Mirai Industry Co., Ltd.

60-1, Block H Platinum Walk, Jalan Langkawi, Setapak 53300

The Kaizen Japan Study Tour

Day 5 - Friday Japan Culture

60-1, Block H Platinum Walk, Jalan Langkawi, Setapak 53300

The Kaizen Japan Study Tour

City Information - KYOTO

60-1, Block H Platinum Walk, Jalan Langkawi, Setapak 53300

The Kaizen Japan Study Tour

60-1, Block H Platinum Walk, Jalan Langkawi, Setapak 53300

The Kaizen Japan Study Tour

Study Tour Details and Registration

(6th 12th November 2016)

Group Fee: 3 and Above

Note: 6% GST is NOT included

Postal Address: _________________________________________________________________________

60-1, Block H Platinum Walk, Jalan Langkawi, Setapak 53300

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