Lean construction training in Japan

We will be waiting at the arrival airport. Check in to hotel.

Overnight: Tokyo | Dinner

About TPS and Lean
Nearly 30 years ago, Lean was presented as the generic version of TPS.
Actually, Lean was an interpretation of TPS – a rather poor interpretation.
Then, over time, Lean drifted farther away from TPS, thus making it far less of a generic version of TPS and more its own unique thing.

“Difference”
The lean production method is packaged even as a production management method, and a set of texts, checklists, and standards required for introduction is provided as a package from a consulting company.

TPS – Do you really understand what is waste? –
The basic philosophy of TPS(Toyota production system) is the reduce the manufacturing costs by removing complete all unnecessary (waste).

There are two basic ideas.

1) jidoka
“jidoka” is not just automation.
“jidoka” (which can be loosely translated as “automation with a human touch”), as when a problem occurs, the equipment stops immediately, preventing defective products from being produced.
Avoid making defective products, rather than finding defective products by inspection.

2) Just-in-Time
Making only “what is needed, when it is needed, and in the amount needed”
Just-in-Time is a production method that responds to diversifying consumer needs. Even in small-lot production of many kinds, work in process can be eliminated, and production can be performed with less cost and in shorter time.

Etymology of Just-in-time
A word from Toyota Motor’s founder Kiichiro Toyoda: “Car parts are best collected just in time.”

Ways to increase productivity

– “Visualization and Clean up” –

After the accident occur, we can notice it’ problems. (Usually the problems have been hidden. )
The visualization bring problems into surface.
Therefore,we must cleaning out.

Visualization and Clean up can also effective another various things.

The shortening of work hours

Prevent machine failure

Human resource education

Industrial Safety and Health

Delete search time

– “Stop behavior that has no value to the customer” –

Useless work increases more useless behavior and ultimately compressed the management.
Is that work worth with be paid for the customer?
Site managers should seek to more simplify their work. If you do it that, no matter who does it, the same quality can be made possible.

Overnight: Tokyo | Breakfast,lunch and Dinner

Example
Tokyo Metropolitan Government buildings
The 243-meter tall Tokyo Metropolitan Government buildings use various earthquake-resistance technology, including these giant shock absorbers.
Seishin, Vibration control : The building is equipped with dampening devices (like shock-absorbers) designed to dissipate kinetic energy.
Menshin, Base isolation : There is a device separating the building from the ground which prevents shock waves from being transmitted to the structure.
Taishin, Basic earthquake resistance: The walls and/or load-bearing pillars are reinforced with specific stiffening materials to make them stronger against shaking.

Tokyo Mokkoujou by SHIMIZU CORPORATION

A rich heritage of woodworking skills handed down since the days of temple and shrine carpenters.
Tokyo Mokkoujou Arts & Crafts Furnishings at Shimizu has refined and passed down traditional skilled techniques used by woodworkers since it opened in 1884.
About 80% of Japanese houses are wooden.
Japanese wooden architecture still uses traditional techniques.In order to fix the tree to the tree without screws and nails, cut the tree exactly and connect it with its part.
Wooden buildings are lighter than other materials, so they are less susceptible to earthquakes and can withstand a magnitude 7 earthquake.

Japanese traditional architecture

Overnight: Tokyo | Breakfast,lunch and Dinner

The number of participants and the tour schedule determine where you can visit.

Example
Arakawa River Control
Rivers change greatly with the growth of the city.
A catastrophic flood occurred in Arakawa in 1910.
Fundamental flood control measures were planned through this flood, and dredging was completed over 28 years. Since then, straightening of the channel and strengthening of the embankment have been performed to this day.

Example

Recycling of construction waste
The technology of the Japanese construction industry, which is environmentally friendly, can be confirmed in waste disposal.

Overnight: Tokyo | Breakfast,lunch and Dinner

An example of visit factory

Nissan Yokohama Plant

Nissan Motor’s Yokohama Plant is the first mass-production plant in Japan.
You can see not only production equipment that has become more automated, but also the QC circle activities at the top level in Japan.

Factory profile
Site area : approx. 537,000 m2 (including welfare land)
Number of employees : approx. 3,300 (as of June 2019, including development department)
Production capacity : 470,000 units / year (excluding overtime and leave)
Production items : Engine units (VK, VR, MR, KR)Motor unit (EM57, HM34, RM31)Suspension processing / welding parts, aluminum casting parts, axle processing parts, catalyst parts, forged parts

At the “Karakuri Improvement” exhibition in 2019, the Nissan Yokohama Plant was awarded several improvement activities.

Overnight: Tokyo | Breakfast, lunch

Sightseeing in Kamakura
Kamakura is an ancient city that has produced its own, original culture.
Once it was a political capital along with Nara and Kyoto, and was also the birthplace of Japan’s first samurai government, the “Kamakura shogunate.” Warrior Minamoto no Yoritomo was appointed as Seii-Taishogun (shogun) by the Imperial court in 1192 and established the Kamakura shogunate, which was the first samurai government in Japan, whereas previously the Imperial court in Kyoto had held power.

Shin-Yokohama Ramen Museum is a building that well expresses the atmosphere of the Showa era in Japan.
For Japanese, ramen is a very familiar and favorite food.
It’s no wonder there are people who eat ramen every day.
Ramen has a variety of flavors, and you can easily eat delicious ramen at the Ramen Museum.

Overnight : Tokyo | Breakfast ,Lunch and Dinner

The Tokyo Wan Aqua-Line Expressway
[Overview]
Road Name: Tokyo Wan Aqua-Line Expressway
Road Number: National Highway No.409
Road Length: 15.1 km
Total Construction
Cost: Approx. 1.44 trillion
yen
Date Opened: Dec. 18, 1997

[Tokyo Wan Aqua-Line’s construction]
The Tokyo Wan Aqua-Line Expressway consists of two-10km long tunnels (Aqua Tunnel) under Kawasaki waters and a 5 km long bridge(Aqua Bridge) over Chiba waters with two artificial island in between.
Japan’s first marine rest area “Umihotaru” is an artificial island constructed to shift the expressway from the tunnels to the bridge.
There is also a tunnel ventilation tower callded “Kazenotou (Tower of Wind),” on the artificial island in the mid-section of the undersea tunnel and a pyramid shaped Ukishima Ventilation Station near the tunnel entrance on the Kawasaki side.

Construction Technology Exhibition Hall (Ministry of Land)

We will send you to the departure airport.