On-Site Practical Training for Enhancing Production Capabilities

The “Production Site Enhancement Training” is a participant-driven, hands-on TPS improvement seminar conducted at your factory by an instructor using tailored teaching materials.

This training provides participants with the knowledge and techniques to cultivate the ability to identify waste and strengthen improvement skills, aiming to help factories achieve high quality, high productivity, and short lead times.

　Through hands-on exercises and the practical application of improvement methods using optimized teaching materials, participants will acquire the ability to drive cost-reduction activities and master cost-reduction techniques upon completing this training.

Seminar Highlights

Seminar Overview

Title “Production Site Enhancement Training (Three-Session Course)” On-Site Practical Training for Enhancing Production Capabilities
Category Manufacturing Improvement / On-Site Training Training for Production Sites
Format Three-Session Course (3–4 Hours per Session)
Training Content
  1. Lecture:
    – How to conduct improvement activities
    – Overview of 5S and the Toyota Production System (TPS)
    – Explanation using photos and case studies
    – Understanding the importance and necessity of continuous improvement efforts
  2. Hands-On Training:
    – Understanding various types of waste
    – Learning methods to eliminate waste
    – Utilizing teaching materials for a deeper comprehension
  3. Practical Application:
    – Participants will be divided into teams to work on improving assembly processes.
    – Each team will present their results and findings.
Schedule To be determined in consultation.
Location At your designated site.
Capacity 30 participants (5 teams)
Fee Starting from ¥300,000 per session (includes materials; excludes transportation, accommodation, and tax).

Seminar Content

Program
Session 1: Lecture
（1） How to Conduct Improvement Activities
  1. What is the Purpose of a Company?
  2. Characteristics of Successful Companies
  3. Purpose and Goals of Improvement Activities
  4. Key Points for Improvement
  5. Employee Motivation and Workplace Vitalization
  6. Basic Principles of Improvement
  7. Aim High
  8. Understanding Costs
  9. Improvement Story

 （2） 5S as the Foundation of Improvement Activities
  • Seiri (Sort): Eliminate unnecessary items from the workplace.
  • Seiton (Set in Order): Arrange items for easy access and efficiency.
  • Seiso (Shine): Keep the workplace clean and maintain equipment.
  • Seiketsu (Standardize): Standardize processes to sustain organization.
  • Shitsuke (Sustain/Discipline): Cultivate a habit of following rules and maintaining order.


    • （3）Toyota Production System (TPS)
    1. Jidoka (Autonomation)
    2. Just-In-Time (JIT)

    （4）Case Studies
    Session 2: Hands-On Training
    （1）Techniques to Identify and Eliminate Waste:
  • Waste in Movements: Streamlining actions to reduce unnecessary motion.
  • Waste in Storage: Optimizing inventory and reducing overstocking.
  • Waste in Waiting: Improving workflow to minimize idle time.

    • （2） Improving Productivity in Line Operations:
  • Enhancing line balance efficiency to maximize output and reduce bottlenecks.

    • （3）Flow Production and Multi-Process Handling:
  • Understanding the differences between batch production and one-piece flow production.
  • Identifying the benefits of flow production in reducing lead time and inventory.

    • （4）Flexible Production and Workforce Optimization:
  • Techniques for multi-process handling to create flexible production systems.
  • Strategies for reducing workforce requirements without compromising productivity.

    • （5） Separating Human and Machine Tasks:
  • Optimizing workflows by addressing machine cycle waiting times.
  • Delegating tasks efficiently between humans and machines for better resource utilization.
    		•  （6）Explanation of Production Analysis Materials
    1. P-Q Analysis
    2. Process Route Chart:
    3. Flow Analysis
    4. Work Analysis
    5. Transport Activity Analysis
    6. Setup Analysis
    7. Time Analysis
    8. Standard Work
    9. Line Balance Analysis
    10. Production Process Analysis
    11. Operation Analysis
    12. Improvement Item Checklist
    13. Improvement Case Study Format
    Session 3: Practical Application Objective: To apply the concepts and skills learned in previous sessions to real or simulated production processes, enabling participants to implement improvements effectively. Content: (1) Team-Based Improvement Activitie
    （1）Practical Improvement Implementation
            1.Current State Analysis　2.Identifying Problem Areas　3.Developing Improvement Proposals　4.Implementing Improvement Proposals　5.Evaluating Results　6.Final Presentation
    Application

    Consultants from major companies
    with experience in over 40 countries will respond.
    Please feel free to contact us.

    Online/remote Assessment
    Download documents
    Contact us

    If you are in a hurry, please call us.

    +81-3-5783-3571
    （Japan time）
    Open 08:30 – 17:30
    Except for Saturday, Sunday, holidays, Year-End and New-Year holidays