Tuesday, August 6, 2013

Japan August 2013

5 August
UD Trucks a division of Volvo International
Todays visit focused on pure manufacturing and the ways CI has evolved in the Japanese workplace. UD operate on a workplace 1 hour north of Tokyo on 400ha of factory space and represent 12% of all truck sales in Japan.  3700 employees work on the site and are amongst 9000 nation wide.

Over 1000 model types of trucks are available and purchasing orders are triggers for build operations, right through from engine construction to fabrication of chassis and cabins.

UD rely heavily on 2 CI principals to achieve less than 2% rework;
 Poka-Yoka-: mistake proofing devices to assist employees to complete the value adding task.
Standard Work-:specific work descriptions detailing cycle time, takt time, work sequence and inventory parts required.

The birth place of CI or Toyota Production System (TPS).  Unfortunately photos are not allowed and lone visitors are restricted to where they can travel/talk to.

The two pillars we were presented as the key to Toyota success are;
Just in Time (JIT) manufacturing, to create the product at the correct time in the correct amount to meet the customers needs., once an order has been placed and confirmed, thus removing Muda (waste) and surplus inventory. 
Jidoka: the principal that production line must be stopped if the operator is not achieving 100% quality of value during their specific task.

Jidoka works by empowering the  operator to identify the error, plan to rectify within station takt time, if unable notifies supervisor, they then have a designated time to address, if not achieved line will be stopped until error has been rectified. This practices ensures 100% quality of product makes it to the end station.

Toyota are now listed as the largest car manufacturer in the world and boost that 97% of their vehicles can be recycled back into manufacturing. A very impressive tour even without close access to the CI tools they have been using.

7 August
 Tsukiji Market, Tokyo
230ha of open cry auctioning system for fish and vegetables, destined for the Tokyo population.  An amazing place with no CI or safety foundations evident, quite surprising. 
Tsukiji is famous for its live tuna sales and turns over   $300million yen/day in sales, supports 30,000 employees, moves 7500 tonnes of produce in 24 hours and contributes to an estimated 7.8 billion yen in sales/day for fish&vegetables across Tokyo's 6 markets.
An amazing market space and such a contrary to the organised workplaces visited.

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