Productivity improvement in a factory means maximizing added value with minimal investment.
In other words, being able to make more profit with less cost (manpower, equipment, materials, time, etc.) can be said that productivity is high.

Solve these issues
with productivity improvement in a factory ISSUE

Profit does not grow
Sales do not grow
Lack of manpower
Lack of space
Lead time reduction
Large inventory

3 points
for productivity improvement FEATURES

  • 1

    Thorough elimination of waste
      We thoroughly eliminate waste (actions of no value for customers) from the flows of information and materials.
  • 2

    Utilization of IoT
      In the environment where the flows of materials and information are normal, we will improve Q (Quality improvement), C (Cost reduction), and D (Delivery capability) by utilizing IT.
  • 3

    Thorough measures to prevent recurrence of defects
      If a problem occurs, we investigate causes of the problem in real time and thoroughly take measures to prevent recurrence.
Thorough elimination of waste

While promoting 5S, we eliminate waste of work (waiting, walking, storing, and transportation).
We will eliminate waste of the shop floor, reallocate work with tight allocation of human resources, and promote development of multi-skilled workers according to the reallocation plan.

Utilization of IoT

If you introduce IoT to the shop floor where many issues remain, the issues will not be solved.
You can solve the issues of the shop floor by utilizing IT if you first prepare an ideal environment for manufacturing through organizing the flows of materials and information and eliminating waste.

Thorough measures to prevent recurrence of defects

If you think about only superficial causes when a problem occurs, only the superficial problem can be solved. Therefore, in order to find the root cause of the problem, we conduct “Why-why analysis”.
For one problem, we think “why?” to investigate the factor caused the problem, and think further “why?” to investigate the factor caused that factor.
If you repeat this several times, you will understand the root cause of the problem and will be able to take fundamental measures.

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
Productivity improvement Specialist
ITO, Akihiro

Process improvement consultant

Akihiro Ito is active on the front line as a shop floor improvement consultant. He has improved a wide variety of large and medium-sized shop floors of over 300 companies in more than 12 countries in Japan and overseas, and has solved the problems of each shop floor every time. Based on his experience working on the production control system, he implements improvement activities in all processes of a factory such as sales, materials, production control, manufacturing, and outsourcing. In addition, he implements the improvement activities together with the people at the shop floor, make the culture of shop floor improvement rooted in the company, and realize quality improvement, productivity improvement and lead time reduction.

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