Case Study 1
Optical Instruments Manufacturer Company A

Results
  • Semi-annual targets achievement
  • Practice of PDCA Cycle properly implemented and
  • Formation of personnel with Waste finding and elimination
  • High Capacity to adapt to new models orders

Company A, optical instrument manufacturer, were doing contract manufacturing. Since the main lines of its client have been shifted to overseas, production for domestic market declined more than half. Aiming to recover its contract manufacturing business, Company A used Hirayama Consulting Services.

Industry details
optical instrument manufacturer
Country
Japan
Purpose
Quality improvementCost reductionProfitability improvement
Industry
Others
issues

  • Frequent production stops has affected the production volume and equipment operational availability
  • “achieve the planned production is not needed” mood spreading
  • Low Productivity awareness among technical personnel
  • Analysis
  • Assembly process workload reduction is not possible with current line lay-out
  • Assembly workers motion Workbenches and material placement are cause of waste on Assembly workers Motion.
  • Parts Supply Equipment is not efficiently designed
  • Implementation

  • Planning and setting of semi-annual improvement targets
  • Monthly analysis on current situation: issues, kaizen proposals, results.
  • Daily Improvement tasks by Supervision Personnel
  • Lay-out design review
  • Workbench, parts, jig and tool placement review. Reduction of worker motion, process review.
  • Why did you choose Hirayama Consulting?

    The availability of implement the Toyota Production System while nurturing internal personnel capable of keep continuous improvement was the main reason..

    1. Toyota Production System Basis
    2. Practical improvement rather than lectures
    3. Nurturing personnel able to give continuity to Improvement Policies as a primary objective
    Other major decisive factor was the consistency with our Company orientation.

    Case Study 2
    Automobile Parts Manufacturer Company B

    Effects
  • No. 1 Plant Production Goal achieved by improvement on line usability
  • Elimination of missing parts through Spare parts Control implementation
  • Improvement of awareness of employment productivity and its relation with line stop and production
  • Performance of planned production, enabling measures from Client’s point of view
  • Reducing Cost through Operation availability Improvement Project.

    Industry details
    Automobile Parts
    Country
    Japan
    Purpose
    Quality improvementCost reductionProfitability improvement
    Industry
    Others
    Analysis

  • Line stop causes investigation for different equipment parts conducted
  • Spare parts management system is not efficient
  • Improvement measures, process visualization not existent
  • Lead-time for performance test not appropriate (long)
  • Implementation

  • Improvement Emphasis in eradicate Line stop causes (i.e. coating method review)
  • Elimination of missing parts through Spare parts Control implementation
  • Visualization of improvement and process progress and sharing of issues
  • In-house Performance Tests and Inspection performed simultaneously
  • Why did you choose Hirayama Consulting?

    Have gained a thorough understanding of our worksite and a perfect match of Hirayama with our Improvement activities were the main reason.

    1. Customer Perspective
    2. Production based on Standardization
    3. Pursuit of Plant total optimization
    4. All process visualization management system structure
    5. Personnel training through Improvement activities
    Besides consistence on above items, having received a 3 days worksite research in our plant prior to start the consulting, made us sure about Hirayama commitment.

    Genba Kaizen 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.

    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

    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