A reform on which the company’s fate depends
A four-year project

Result
Productivity 26%UP
Defect rate: Less than 0.1%
Lead time 16-hour reduction
On-time delivery rate of 98%

To survive against foreign products, it was necessary to reduce costs and shift towards a system capable of handling a wide variety of products in small quantities.

The field resists change, but over the course of about a year, worker education (awareness reform) was conducted, and the reform was implemented. The number of improvements per person ranged from 5 to 15 items per month.

During the four-year project, more than 40,000 improvements were made, achieving targets in productivity, defect rate, on-time delivery rate, and lead time for each item.

Industry Details
Precision Machinery
Country
Japan
Company Size
Employees: 100 to 200
Challenge
High-mix, low-volume production
Objective
Profitability improvement
Industry
Electrical and electronic
The background of the reform
Industry trends
  • High-mix, low-volume, and diversified production
  • Shortening product lifecycles
  • Hollowing out of domestic manufacturing due to overseas production
  • Current situation
  • Quality is demanded at the ppm level
  • Cost competition is becoming intense
  • More than 90% are made-to-order, and quick delivery response is urgent
  • Issues
  • Weakness in productivity improvement techniques (approaches)
  • Lagging skill enhancement to cope with increasing product variety
  • Inter-process retention occurring, resulting in longer lead times
  • Innovation schedule
    Key to the success of the innovation
    In manufacturing sites, the comprehensive strength (quality, cost, delivery) enhanced by adhering to the principles of ‘San-Gen (Go to the actual place, Understand the actual situation, Implement actual measures), San-Soku (Immediate action, Immediate production, Immediate improvement), and San-Tetsu (Thorough understanding, Thorough investigation, Thorough implementation)’ enables solving environmental changes and problems surrounding the company

    Specialist in on-site improvement
    Akihiro Ito

    On-site improvement consultant

    Regardless of the industry, instill a culture of on-site improvement within the company, conduct improvement activities together with the people on the ground, and achieve quality improvement, productivity improvement, and lead time reduction. Additionally, through experience in handling production management systems, practice improvement activities in every process within the factory, from sales to materials, production management, manufacturing, and outsourcing

    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.

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

    3 reasons why we are chosen REASON

    REASON 1

    Improvement experience of
    more than 1,500 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.

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