Factory diagnosis is conducted by our experienced consultant to actually visit the factory, grasp what points are important for improvement activities together with the customer, and explain how to proceed to gain agreement with the factory side.

Our consultant with a wealth of experience and achievements conducts the factory diagnosis, identifies issues that customer could not see or notice, using our own radar chart, and recommend an ideal situation the customer should be. Please utilize our factory diagnosis to identify problems, create a foundation for a continuous improvement, or a first step in introducing consulting.

Solve these issues
with factory diagnosis ISSUE

Profit does not grow
Sales do not grow
Poor organization and production control
Profitablitity improvement
Quality improvement
Human resources do not grow

3 points
for factory diagnosis FEATURES

  • 1

    Issues will be clarified
      We make clear recommendations on issues that customers could not notice.
  • 2

    Employees’ awareness improvement
      We propose improvement plans that combine measures for shop floor improvement and employees’ awareness improvement.
  • 3

    Timing of the “factory diagnosis”
      We recommend receiving the factory diagnosis regularly same as a physical checkup for the human body.
Issues will be clarified

At the shop floor, there are issues that cannot be solved by your own company alone for various reasons.
Our consultant with a wealth of experience and achievements conducts the factory diagnosis and issues that you could not see or notice will be clarified.
We will propose an ideal situation your company should be, according to the actual situation of your company’s shop floor, not like a critic to “find a fault”.

Employees’ awareness improvement

When our consultants conduct the factory diagnosis, they ask operators how to work directly at the shop floor, so it is very effective in terms of raising their awareness.
Hirayama Consulting is able to provide consulting guidance that is acceptable to the shop floor workers so that they can continue the culture of improvement even after the guidance is ended.
In the factory diagnosis, we will propose improvement plans that combine measures for the shop floor improvement and employees’ awareness improvement.

Timing of the “factory diagnosis”

“Factory diagnosis”, which accurately checks the status of the factory, is the same as a physical checkup for the human body. If you have a medical examination with your illness getting worse, it will take cost and time to cure your illness. There were some cases that a company tried their best to the very last minute and finally received a “factory diagnosis”, however they could not consider an effective solution for financial reasons.
The timing of the “factory diagnosis” is effective when starting up a new business, planning capital investment or building a new factory, or when business performance is not growing or gradually slowing down.

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

If you are in a hurry, please call us.

03-5783-3571
Open 08:30 - 17:30
Except for Saturday, Sunday, holidays, Year-End and New-Year holidays
Factory diagnostic specialist
ITO, Akihiro

Process improvement consultant

He worked for JIT Institute, Tokyo for 20 years.( JIT: Just In Time). During this period, he has learned Just In Time philosophy and method of improvement of productivity in manufacturing plant. Continuously he has been engaged in effective introduction process of Production Management System to small and medium enterprise and even big enterprise.

Case example of Gemaba Kaizen RESULTS

Acquired orders from two new customers
by improving quality.

We reduced most work-in-progress inventories and defective inventories, which were found throughout the factory, and reduced manpower, and now we almost no longer receive customer complaints that we had every month before. (Automobile industry / Plant manager)

Turn the factory into a showroom
in order to improve profitability

We improved 250 cases out of 300 cases pointed out by the 5S patrol conducted for one year. The factory was realized to be the showroom and also achieved cost reduction of 30 million yen per year. (Metal processing / Director)

Productivity Up to 169.6%
by 6 months of improvement activities

the Japanese president decided to outsource a shop floor improvement consulting to have their shop floor checked, and asked us, Hirayama Consulting.(Auto parts manufacturer/Managing director)

3 reasons why we are chosen REASON

REASON 1

Improvement experience of
more than 1,000 companies in 40 countries

There must be the shop floor issues that cannot be solved by your own company alone. Improvements and reforms for manufacturing industry to survive, regardless of country or industry, need development of your human resources through practical experiences of improvement, and strengthening of your production system base.

REASON 2

Consulting that shop floor workers
acknowledge our superiority and be pleased

In conventional consulting styles, there was a distance between consultant and the shop floor because it was promoted mainly consultant and management executives. Our consultant can provide a guidance without a distance between consultant and the shop floor through the guidance based on the "seeds of improvement" in a concrete way, instead of "finding fault" like a critic.

REASON 3

Continuous improvement will continue
even after the end of guidance

While strengthening "human resource development", we focus on the "overall flow" from design to purchasing, manufacturing, logistics, and production control, and provide guidance that matches the actual situation of your company. Continuous improvement will continue even after the end of guidance through the guidance that is acceptable to the shop floor workers.

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

If you are in a hurry, please call us.

03-5783-3571
Open 08:30 – 17:30
Except for Saturday, Sunday, holidays, Year-End and New-Year holidays