We introduce some of the achievements that our experienced consultants have provided highly effective consulting both in Japan and abroad based on the TPS (Toyota Production System), cooperating with the work implementation team
Gemba KAIZEN Consulting (Vietnam)
[Results]- On-line/remote guidance for Gemba KAIZEN Consulting for Overseas Plants!
- It is the advantage of on-line consulting that makes possible for sharing customer’s specific instruction materials instantly.
[Purpose]
Quality improvement
Electrical and electronic
IOT Kaizen Digitization of Analog Meters
[Results]・The time required for meter monitoring and data entry work was reduced from 15 hours/month (360 Kyen/year) to 0 hours/month
・Abnormal condition is reported in real time on smartphone. So, quick action is possible.
[Purpose]
Quality improvementProfitability improvement
food
Autonomation (JIDOKA) improvement in electrical device manufacturing
[Results][Purpose]
Profitability improvement
Electrical and electronic
Remote Gemba (on site)KAIZEN: KAIZEN without entering a factory
[Results]Before KAIZEN Total Cycle Time 940”
⇓
After KAIZEN Total Cycle Time 700” Production Volume 30% increase
[Purpose]
Profitability improvement
Metal
From the lot production to the one-piece flow production
[Results]- Lead time reduction: 40%
- Necessary manpower for assembly: 16 operators → 6 operators
- Space: 200㎡ → 110㎡
[Purpose]
Profitability improvement
Electrical and electronic
Improvement in Vietnam factory – Productivity Up to 169.6%
[Results]- Productivity Up to 169.6% by 6 months of improvement activities
- Now the customer can implement high-level improvements that they could not solve by themselves!
[Purpose]
Cost reduction
One-year improvement project for factory profit
[Results]- Productivity – 30% UP
- Secure process for new products by layout change – 100㎡
- Reduce process operators – total 20 operators
[Purpose]
Cost reductionProfitability improvementLead time reduction
Electrical and electronic
Kaizen Examples
[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
[Purpose]
Quality improvementCost reductionProfitability improvement
Others
Make a deficit factory overseas profitable
[Results]- Turn profitable two years after the start of improvement activities.
- Acquired orders from two major new customers by improving quality.
[Purpose]
Quality improvement5sProfitability improvement
Others
Example of introducing the lean product system (* 1) at an overseas local factory
[Results]- Setup time reduced by 50 %
- Productivity increased 30 %
- Lead time reduction 30 %
[Purpose]
Cost reductionLead time reductionOthers
Automobile
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.
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Except for Saturday, Sunday, holidays, Year-End and New-Year holidays
