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| Many production managers have theoretical knowledge about Kaizen ("lean operation"), JIT ("Just-in-Time") and "Autonomation ". They do not know, however, how to incorporate Kaizen systems in their own workplace (Gemba). Unfortunately, trying to bring book knowledge to bear on complex problems in the real world generally proves impractical or ineffective at best, if not actually counter-productive. All SGC consultants have worked for major Toyota group companies, such as Isuzu Motors, Toyota Auto Body, and Rinnai, where "lean operation" has been vigorously pursued. This has given them practical, hands-on experience as employees in solving day-to-day problems through application of Kaizen activities in successful manufacturing businesses. Having the benefit of SGC's accumulated know-how is the most significant factor in improving your productivity and profits. |
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| SGC's on-site consulting services are extremely effective in the following situations: |
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- Your operation needs dramatic improvement without major changes in your current
systems, equipment, and/or location. We call this work " Gemba Kaizen". Through Gemba Kaizen, your own staff develops practical solutions providing immediate improvement, which results in reduction of total production and/or operating costs. Gemba Kaizen is not a one-time activity, but should become an integral part of day-to-day operations. SGC will help your staff learn to continuously apply Kaizen techniques in their daily workflow.
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- Your current logistics create a bottleneck in your lean operations. The Logistics Kaizen incorporates Kaizen methods in logistics within one manufacturing site, or between separate locations. Moving materials/products from one location to another is one of the most commonly wasteful activities, causing lost time and excesses or shortages of materials and/or manpower, etc. Logistics Kaizen focuses on scheduling and ordering techniques, material/product and information flow, delivery systems, implementation of the Kanban and Heijunka ("level production") systems, and customer and supplier relationships. Inefficient logistical systems will actually cancel out even strenuous Gemba Kaizen efforts, which means that Logistical Kaizen must be implemented at the same time as Gemba Kaizen is undertaken. Logistical Kaizen is also very effective when applied in distribution industries, such as courier services.
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- Planning for a new product, new production site, or complete replacement of the existing site, has commenced. We call this work "3P" (Production, Plant or Process Preparation Process) or "New Production System Development". Although Gemba Kaizen is a very useful activity, its effectiveness is limited because it is executed on an existing system where fundamental changes cannot be undertaken. When a new product and/or new production site is considered, we strongly recommend that an SGC consultant be included in the development phase. Our consultant will work closely with your design team for creating the best production system possible for your new product.
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