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Towards World Class Manufacturing

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Pre-briefing & visit Honda on 09 October

Introduction

Posted by smeding on 29 October, 2006

On October 6th a pre-briefing session was organised by the EU-Japan centre.
The meeting place was at the Shereton airport hotel in Brussel (Belgium).
After a cup of coffee we started with an introduction round.
Very interesting to see and hear that we were really a representation of the EU.
From Finland to Spain and from England to Hungary, 24 participants from all over Europe.
See Participants November 2006 for the participants list.

The attendees from the EU centre were;

  • Dr. Richard Keegan, EU advisor to the WCM mission
  • Ms. Mika Kobayashi, Manager Topical missions Tokyo centre (and guide during Japan trip)
  • Mr. Shiro Akiyama, Japan-side Director EU-centre
  • Mr. Simon Craig Gray, deputy director EU-centre
  • Ms. Celine Godart, Programme Manager
  • Ms. Maki Saito, Programme Coordinator

The staff of the EU centre gave a general presentation about the EU centre and a presentation of the updated program of the WCM course in Japan.

Dr. Keegan gave several useful tips about cultural issues and how to organize the factory visits.

Culteral tips;

  • Japan is not a creditcard society, take enough cash with you.
  • handover/receive a businesscard with respect
  • the food is very good, but less energetic as European, take for example energy candy bars with you.
  • power is 110V at 60Hz, take care of an adapter.
  • Japan is a gift culture, consider some small gifts for the atendees;
  • put your name in Japanese on the backside of your businesscard.

Organize factory visits and Question and answer sessions;

  • prepare in advance a set of key questions for the visits;
  • check if the questions are answered/clear after the fatory tour;
  • devide the tasks during the factory tour, gatherers (collect info from guide) and hunters (look & speak with operators)
  • ask if taking fotos is allowed, propose eventual one fotographer (with a simple camera);
  • explain before the Q&A session how you have organized;
  • dedicated spokesmen and secretaries;
  • summarize and report during travel.

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WCM program in Japan

Posted by smeding on 29 October, 2006

Study block I:
Lectures, seminars & panel discussions, presented by experts from Japanese industry covering subjects such as:

– Lead-time reduction through streamlined flows of information and products;
– Policy deployment, HR management and best practice for staff motivation;
– Continuous improvement of customer service supported by WCM;
– Lean thinking and WCM approach in Japan;
– TQC, TQM, TPM, JIT and TIE;
– Attractive quality creation;
– Levelled production system;
– Variable-product variable-quantity production to meet demand fluctuation;
– Synchronized production system (from order to delivery);
– Flexible manufacturing implemented by QCD;
– Improvement of overall manufacturing capability.

Study block II:
Visits to companies – preparation for company visits and post-visit reviews. The sectors of activity of the companies to be visited include, among others:

– Chemical products and plastics;
– Machinery;
– Steel products;
– Automobile industry.

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Program description

Posted by smeding on 29 October, 2006

INTRODUCTION
Many WCM-advanced Japanese manufacturing firms have enjoyed considerable success largely through their adoption, use and development of unique manufacturing principles. Japanese production methods offer the best practice in production, cost deployment, quality assurance and lean production. Flexible production systems respond rapidly to changing customer needs and help maintain competitiveness.

The World Class Manufacturing programme provides an in-depth analysis of Japanese manufacturing methodology.

This intensive 6-day high-level mission in Japan is aimed exclusively at EU managers and executives responsible for corporate strategy in manufacturing management with knowledge of WCM and an engineering background.

Participants will acquire a better understanding of WCM approach (TQC, TQM, TPM, JIT, TIE), Lean Manufacturing and Continuous KAIZEN to maximise human resource and manufacturing capabilities.

The training course which is mainly tailor-made according to the participants’ needs consists of lectures, workshops and visits to leading WCM Japanese factories to understand the real “Gemba” (production site), to talk directly with Japanese production engineering managers, and to observe the effective implementation of manufacturing methods.

A preliminary visit to an industry applying WCM methods is held in Europe, as well as a pre-departure briefing session, prior to the training in Japan.

TARGET SECTOR
Manufacturing companies from the European Member States.

PARTICIPANT PROFILE
The candidates should be:
– division directors or industrial directors;
– managers and executives Operation & Logistics;
– plant managers, directors of Quality and Excellence;
– managing directors in manufacturing companies.

ELIGIBILITY
The candidates:
– must be citizen of an EU Member State;
– must work for an organisation that is >50% EU;
– must be supported by their employer and be able to participate in the entire programme;
– must have a reasonable command of English;
– should work at a decision-making level for an industrial manufacturing company and/or;
– should be involved in changing production engineering methods /strategy and / or production control;
– should have approximately of 10 years’ experience in operations management and/or;
– should have a good knowledge and practice of production methods of excellence.

SELECTION CRITERIA
The main criteria for selection are:
– the professional & educational background of the candidate;
– the production methods and production strategy in relation to KAIZ

EN, JIT & TQM of the applicant’s company.
In order to ensure a high degree of personal attention, the number of participants in each programme is limited.

PROGRAMME OBJECTIVES
The purposes of the mission in Japan are:
– to discover the Japanese approach towards world-class manufacturing;
– to discern and learn how Japanese firms achieve superior production standards;
– to focus on how Japanese manufacturing companies optimise the production engineering flow / process for manufacturing excellence and on how Japanese companies achieve lean manufacturing by visiting the top manufacturing plants in Japan;
– to visit the real “GEMBA” (i.e. production site in Japan);
– to talk directly with Japanese production engineering managers.
In a nutshell, this course brings EU companies closer to WCM performance.

PROGRAMME DESIGN AND CONTENT*
Study block I:
Lectures, seminars & panel discussions, presented by experts from Japanese industry covering subjects such as:

– Lead-time reduction through streamlined flows of information and products;
– Policy deployment, HR management and best practice for staff motivation;
– Continuous improvement of customer service supported by WCM;
– Lean thinking and WCM approach in Japan;
– TQC, TQM, TPM, JIT and TIE;
– Attractive quality creation;
– Levelled production system;
– Variable-product variable-quantity production to meet demand fluctuation;
– Synchronized production system (from order to delivery);
– Flexible manufacturing implemented by QCD;
– Improvement of overall manufacturing capability.

Study block II:
Visits to companies – preparation for company visits and post-visit reviews. The sectors of activity of the companies to be visited include, among others:

– Chemical products and plastics;
– Machinery;
– Steel products;
– Automobile industry.

(*) The precise content of the programme and its schedule are currently being determined and are subject to modification. A detailed timetable will be available upon request.

COSTS
The EU-Japan Centre covers all costs directly related to the programme i.e. lectures, seminars, group study trips (including travel outside Tokyo). It will also cover transport and hotel costs for the pre-departure meeting in Europe. The participant’s company is expected to cover the participant’s travel costs to and from Japan as well as living expenses in Japan including accommodation.

COURSE LEADER AND EU ADVISOR
The course leader is Professor Dr. Hajime Yamashina, from the Department of Precision Engineering, Graduate School of Engineering, Kyoto University.
A worldwide authority on manufacturing strategies and practices, he is a Fellow of the Royal Society of Arts (UK), a Member of the Swedish Royal Academy of Engineering Sciences and the Director of the Japan Society of Plant Engineers.

The EU advisor
Dr. Richard Keegan – Enterprise Ireland, a specialist in the fields of World Class Business and Benchmarking. He has focused on adapting these concepts for SMEs, working closely with a large number of SMEs helping them to implement improvement actions. An author of several books on the topics, he is a lecturer at Trinity College. He has led the DG Enterprise & Industry Benchmarking Initiative and the European Benchmarking Forum and Network, for the European Commission.

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Briefing session

Posted by smeding on 29 October, 2006

As preparation for the WCM course in Japan, a pre-briefing session was organized in Brussel.
Part 1 of the session was an introduction of the program and of the participants.
Part 2 was a visit to the Honda Logistic centre in Gent.

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