Master Class in Lean Production

Transcription

1 Master Class in Lean Production 15th-23th November 2014 Practical Workshop in Japan Understanding the Lean techniques and upgrading the change management capability

2 Master Class In Lean Production Objectives The present study tour proposal is to offer a special chance to go & learn at the source from those who have developed and have been applying with success and for years the methods and the management principles finalized to the attainment of economic results and corporate development. The Master Class in Lean Production business trip represents a unique occasion to learn from Japanese sensei (masters) and directly apply the Lean Thinking tools in the genba. We will encourage participants to: Watch first hand application of the Lean principles in companies of the Toyota Group; See live the application of the most advanced techniques of operations management and verify which methods and tools can be replicated in Europe; Learn how to use the operations management techniques and the Lean Production methodologies; Understand how to apply the tools in one s own company, fostering the involvement of people.

3 Master Class In Lean Production Participants The trip is addressed to entrepreneurs, managers and change facilitators of manufacturing or service companies having already started a transformation path with a Lean view or willing to evaluate the opportunity of implementing a change management project. The participants will be helped and guided in Japanese territory by expert consultants of JMAC Europe who will foster the focalization of attention on the most important points of the visits through moments of preparation and of collective reflection. The Japanese teachers are professionals with several years of experience, not only in the realization of courses, but also in the practical and operational management of factories in the Toyota Group. Particular importance is placed on direct communication and debate with the teachers: to facilitate the conversation with our teachers and guides the group will be accompanied by an interpreter of JMAC Europe, with a deep knowledge of both the language and the topics being considered.

4 Japanese Partners The workshop will be realized thanks to the cooperation of two JMAC partners: GPS Training Center: a Japanese research and training center specialized in the management of production and of operations. The Training Center is also used by several Japanese companies, including Toyota itself, for the training of their manpower. GIFU Shatai: a company whose stock capital is owned by Toyota Motor Company. They are specialized in the realization of commercial and special vehicles such as delivery vans, minibuses and custom vehicles. Part of the lessons will take place directly in the genba of GIFU Shatai, where it will be possible to see original applications of the Lean production.

5 Contents of the journey The trip will focus on the theoretical-operational transfer of the TPS principles and methods through the alternation of practical sessions at the Gifu Shatai plants, and classroom sessions at MIC s premises. The training days will be focused on knowledge about specific themes, with the following objectives: Becoming open minded about the new productivity concepts extended through the direct verification in a best practice company Learning to manage resources Learning the Lean Production techniques Identify solutions to improve the logistic and productive processes at one s own company There will also be moments of interaction between trainers and participants. Both briefing and debriefing will be intended to clarify and conceptualize any points detected during the visits, contextualizing the applicability of the lean principles with the companies of participants.

6 Agenda Saturday: Sunday: Departure from Milan Malpensa or other airport Arrival in Japan Monday / Friday: Understanding the Toyota Production System Comprehension of the TPS applications through visits to Gifu factory of Vehicle Body Corporation Understanding problems at one s own company Research of solutions Practical realization of a One Point Kaizen Drawing up an Action Plan for implementation Summary and final debate Visit to one plant of the Toyota Motor Corporation Group Saturday: Sunday: Free day for shopping and sightseeing Departure from Tokyo and arrival at Malpensa or other airport

7 The cost of the trip is 8, ( +VAT) per participant all inclusive. The amount is inclusive of: Airfare to/fro Japan (Economy class) Visits to companies All internal transfers, Lodging at 4-stars hotels, Insurance coverage All dinners and lunches during the stay in Japan (except the meal on the free Saturday). Moreover, the fee includes the support of qualified consultants of JMAC Europe s, the logistic and training support of JMAC Tokyo, and the guide of experienced interpreters during the entire permanence. The number of participants is limited to a maximum of 15 people, which is why JMAC Europe may reject any requests exceeding such threshold number. Requests for participation must be submitted to JMAC Europe by and not after one month prior to departure. To be considered valid they must be forwarded along with payment receipt. Cancellation: The participation to the trip can be cancelled and the expense totally refunded by and not after one month before departure, which is the deadline for the release of flight tickets. For cancellations after that date and 15 days before departure, JMAC Europe reserves the right to keep as penalty the sum of 1,500 as partial coverage of the cost of the flight ticket already issued and not refundable. Any cancellation or variation request submitted further beyond that timing will not be refunded at all. Pricing

8 Outline of Gifu Shatai Company Profile Address: Mitsuike-cho Unuma Kagamihara-shi Gifu Prefecture, Japan Established in: October 1940 Shareholders: 30% Toyota Motor Company, 30% Hoshino family (founders), 40% other investors Stock capital: 1,175,000,000 Yen (8,500,000 ) Turnover: 35,000,000,000 Yen (253,000,000 ) Employees: About 1,600 Products: Small vans (1,5t. 4,0t.), Van (Hi-Ace), Special vehicles (e.g. Ambulances), Components for Toyota (seats, gearings, wheels, etc.) Factory features Excellent example of production with high mix and small lots, based on JIT concepts Many visitors, not only external, but also from Toyota itself to see their efficient system of production. High Quality: components = 3 ppm, vehicles = 40 ppm Great employment of visual management techniques Cell production managed autonomously by multi-skilled operators Massive usage of Kanban systems for the management of components, which is also being adopted with suppliers who replenish the line in free pass regime