TPS Dojo (1-Day Edition) | Genba Kaizen Consulting by Hirayama Consulting

This training is a one-day program combining lectures and practical sessions to master the TPS mindset and perspective, aiming to enhance production site capabilities.

Participants will gain fundamental attitudes, specialized knowledge, improvement techniques, and the ability to guide subordinates in improvement, reflecting the world-class manufacturing standards.

By enhancing both theoretical knowledge and practical skills, supervisors and leaders in the manufacturing department—equipped with the ability to manage people—can spearhead improvements that yield tangible and effective results.

This TPS practical training is led by a certified trainer who has supported Toyota Motor Corporation’s production sites for over 40 years.

TPS Practical Training Dojo: Explained Through Video

Seminar Overview

Title	TPS Dojo (1-Day Edition)
Category	TPS Doujo
Schedule	Decided after consultation *Please let us know your desired date.
Schedule	09:00–17:00 (1-hour lunch break) ※Meeting Time:08:45
Capacity<	20 participants (please consult us if more than 20)
Place	Our training center (1-84-1 Miyama-cho, Toyota City, Aichi Prefecture) TEL：（0565）71-5288 Click here for the map From Meitetsu Mikawa Line Tsuchihashi Station, approximately 10 minutes by taxi. Please note that parking spaces are limited. If you plan to arrive by car, kindly inform us in advance.
Instructor	Tadamasa Ishigaki、 Mitsu Suzuki、 Matsuki-aoyama
Certificate of Completion	The certificate will be presented upon completion of the seminar.
Fee	55,000 yen/person (tax included) 　 Transportation, accommodation, and lunch costs are not included.

Training content

Program

Lecture : Basics of TPS
1. Importance of cost reduction （1）Corporate purpose （2）Importance of cost reduction 2. Basic concept of Toyota Production System （1）Aim of Toyota Production System （2）Two pillars of Toyota Production System （3）Kanban and material flow （4）Lot production and leveled production （5）Three basic principles of JIT （6）Two pillars of Toyota Production System （7）Difference between automation and jidokatization （8）Another jidoka （9）Built-in quality	3. Idea of improvement （1）Work improvement and equipment improvement （2）Purpose of improvement （3）Recognizing waste （4）work and waste （5）Types of waste （6）Apparent efficiency and true efficiency （7）How to think when coming up with an idea 4. Standard Work （1）What is standard work? （2）Standard work conditions （3）Characteristics and Three Elements of Standard Work” （4）Standard Work Combination Sheet
Practice
1.Understanding and considering current issues （1）Measuring working time （2）Measuring element work time （3）Manual time/automatic feed/walking time （4）Extracting problems (3 steps, 1 person work) （5）Summary of problems (by group) （6）Explanation of the problem (with demonstration) 2. Consideration and implementation of improvement plans （1）Consider the layout for 2-process/2-person work （2）Confirmation of improvement plans and explanation of TPS method （3）Practice according to improvement steps （4）Verification based on the principle of improvement （5）Root Cause Analysis ⇒ The 5 Whys （6）Comparison and verification of improvement effects （7）Improvement practices and horizontal expansion （8）Measuring work time after improvement	3．Save people and strengthen workplace capabilities （1）Confirmation of improvement effect （2）Purpose of the Suggestion System （3）How to Promote Labor Reduction Using a Yamazumi Chart （4）Key Points for Utilizing Personnel through Labor Reduction （5）Workplace management methods to increase workplace power

Lecture : Basics of TPS

1. Importance of cost reduction
（1）Corporate purpose
（2）Importance of cost reduction

2. Basic concept of Toyota Production System
        （1）Aim of Toyota Production System
        （2）Two pillars of Toyota Production System
        （3）Kanban and material flow
        （4）Lot production and leveled production
        （5）Three basic principles of JIT
        （6）Two pillars of Toyota Production System
        （7）Difference between automation and jidokatization
        （8）Another jidoka
        （9）Built-in quality

3. Idea of improvement
        （1）Work improvement and equipment improvement
        （2）Purpose of improvement
        （3）Recognizing waste
        （4）work and waste
        （5）Types of waste
        （6）Apparent efficiency and true efficiency
        （7）How to think when coming up with an idea

4. Standard Work
        （1）What is standard work?
        （2）Standard work conditions
        （3）Characteristics and Three Elements of Standard Work”
        （4）Standard Work Combination Sheet

Practice

1.Understanding and considering current issues
        （1）Measuring working time
        （2）Measuring element work time
        （3）Manual time/automatic feed/walking time
        （4）Extracting problems (3 steps, 1 person work)
        （5）Summary of problems (by group)
        （6）Explanation of the problem (with demonstration)

2. Consideration and implementation of improvement plans
        （1）Consider the layout for 2-process/2-person work
        （2）Confirmation of improvement plans and explanation of TPS method
        （3）Practice according to improvement steps
        （4）Verification based on the principle of improvement
        （5）Root Cause Analysis ⇒ The 5 Whys
        （6）Comparison and verification of improvement effects
        （7）Improvement practices and horizontal expansion
        （8）Measuring work time after improvement

3．Save people and strengthen workplace capabilities
        （1）Confirmation of improvement effect
        （2）Purpose of the Suggestion System
        （3）How to Promote Labor Reduction Using a Yamazumi Chart
        （4）Key Points for Utilizing Personnel through Labor Reduction
        （5）Workplace management methods to increase workplace power

TPS practice dojo with video

Application