Cost reduction in a factory means reducing costs by eliminating waste and making only good products efficiently.

We thoroughly eliminate waste from the flow of information and materials.

Solve these issues
with cost reduction in a factory ISSUE

Lead time reduction
Profitability improvement
Profit does not grow
Excess personnel
Large inventory
Lack of space

3 points
for cost reduction FEATURES

  • 1

    Shop floor improvement
      Thorough elimination of waste by 5S, work improvement, equipment improvement, and layout improvement.
  • 2

    System improvement
      Elimination of waste by fundamentally changing the production system of the entire factory (company) from order to production and to delivery.
  • 3

    Operator training
      Achievement of cost reduction by improving quality and productivity through creating correct standardized work and training operators to follow it.
Shop floor improvement

We make improvement effects of 5S, safety, inventory reduction, productivity improvement, and defect reduction by thoroughly eliminating waste in the workplace through work improvement, equipment improvement, and layout improvement.
We conduct as follows: Step 1: 5S activities, proposal system, launching small group activities, Step 2: Work improvement, equipment improvement, layout improvement, Step 3: Quality improvement.
It is mainly conducted by general employees, assistant managers, deputy manageres, and managers.

System improvement

By changing the system of the “flow of information and materials” with the preceding and following processes, we make improvement effects of lead time reduction, work-in-process inventory reduction, productivity improvement, and defect reduction.
Step 1: Work improvement, equipment improvement, and layout improvement in consideration of making a line and manpower reduction, Step 2: Improvement of production instruction method and making it smaller lot
It is mainly conducted by deputy managers, managers, and general managers.

Operator training

We will make a system to establish a correct work method and train operators to follow it in order to develop human resources who will create a strong shop floor, and improve the quality and productivity through the practical trainings for each operator.
In order to establish a correct work method, we make the three documents for establishing standardized work and job instruction sheet, and provide work element trainings for operators.
For practical trainings, we conduct as follows: Step 1: Show the shop floor and teach the operation orders, key points, and know-how, Step 2: Training for the speed of disassembly and assembly operations, Step 3: Let operators make standardized work and “stop, call, and wait” thoroughly in case of abnormality.

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
Cost reduction Specialist
KOSAKA, Zenji

oyota Motor Corporation, Shinmei Co. Ltd.

He was trained by Mr. Taichi OHNO, a pioneer of TPS (Toyota Production System), from the system’s infancy and had the opportunity to put the theory into practice. To KOSAKA, who continues to pursue the principles of TPS, the driving force of ‘Kaizen’ (continuous improvement) has always been people. His motto goes like this – “if you want someone to work, show him how to do it, explain it, let him try it, and don’t forget to praise him if he does a good job”. He is also an expert in machining and assembly.

Case example of Genba Kaizen Consulting 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