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© 2009 Factory Strategies Group LLC. All rights reserved. The Japanese Productivity Philosophy and Practices A summary and re-presentation for: A Study Mission Report JAPANESE PRODUCTIVITY By: John M. Burnham, CPIM, Tennessee Technological University Published by: APICS, 1983

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Page 1: The Japanese Productivity copy

© 2009 Factory Strategies Group LLC. All rights reserved.

The Japanese Productivity Philosophy and Practices

A summary and re-presentation for:

A Study Mission Report

JAPANESE PRODUCTIVITYBy: John M. Burnham, CPIM, Tennessee Technological UniversityPublished by: APICS, 1983

Page 2: The Japanese Productivity copy

2© 2009 Factory Strategies Group LLC. All rights reserved.© 2009 Factory Strategies Group LLC. All rights reserved.

Outline

1. Philosophy

2. The Japanese worker

3. Inventory Management

4. Vendor Relations

- KANBAN

5. Technology

6. Challenges

7. Conclusion

Page 3: The Japanese Productivity copy

3© 2009 Factory Strategies Group LLC. All rights reserved.© 2009 Factory Strategies Group LLC. All rights reserved.

1. Philosophy

1. Simplicity

2. Holistic view

3. Excellent plan execution

4. Respect and teamwork

5. Continuous improvement

6. Balance: productivity and quality(higher quality = less waste = lower costs = higher productivity)

Page 4: The Japanese Productivity copy

4© 2009 Factory Strategies Group LLC. All rights reserved.© 2009 Factory Strategies Group LLC. All rights reserved.

The Japanese Productivity

Page 5: The Japanese Productivity copy

5© 2009 Factory Strategies Group LLC. All rights reserved.© 2009 Factory Strategies Group LLC. All rights reserved.

2. The Japanese Worker

• Attitude

• Employees

• Managers

• The interaction

• Money

• Motivation

• Training and Job Rotation

Page 6: The Japanese Productivity copy

6© 2009 Factory Strategies Group LLC. All rights reserved.© 2009 Factory Strategies Group LLC. All rights reserved.

3. Inventory Management

• Very low inventory

• Scheduling

• Uploading

• Delivery

• Unloading

Page 7: The Japanese Productivity copy

7© 2009 Factory Strategies Group LLC. All rights reserved.© 2009 Factory Strategies Group LLC. All rights reserved.

 4. Vendor Relations

• Close relations

• Information sharing

• Vendor close to the user

Page 8: The Japanese Productivity copy

8© 2009 Factory Strategies Group LLC. All rights reserved.© 2009 Factory Strategies Group LLC. All rights reserved.

Production and Inventory Control

KANBAN

• What is it? It’s a signalling system to trigger action

• The essential elements of KANBAN:1. Stockpoint(s)2. A Withdrawal Signal3. Immediate Feedback4. Frequent Replenishment

Page 9: The Japanese Productivity copy

9© 2009 Factory Strategies Group LLC. All rights reserved.© 2009 Factory Strategies Group LLC. All rights reserved.

• When to use KANBAN?

• Benefits

Production and Inventory Control

KANBAN

Page 10: The Japanese Productivity copy

10© 2009 Factory Strategies Group LLC. All rights reserved.© 2009 Factory Strategies Group LLC. All rights reserved.

• Challenges

• e- KANBAN

Production and Inventory Control

KANBAN

Page 11: The Japanese Productivity copy

11© 2009 Factory Strategies Group LLC. All rights reserved.© 2009 Factory Strategies Group LLC. All rights reserved.

5. Technology

• Tools

• Computer technology

• Preventive maintenance

Page 12: The Japanese Productivity copy

12© 2009 Factory Strategies Group LLC. All rights reserved.© 2009 Factory Strategies Group LLC. All rights reserved.

6. Challenges

• Truck transportation

• Workforce

• The protectionist Japanese policy

Page 13: The Japanese Productivity copy

13© 2009 Factory Strategies Group LLC. All rights reserved.© 2009 Factory Strategies Group LLC. All rights reserved.

Remark“The Japanese people appear to be very clean.

Litter is particularly non-existent” Burnham

Page 14: The Japanese Productivity copy

14© 2009 Factory Strategies Group LLC. All rights reserved.© 2009 Factory Strategies Group LLC. All rights reserved.

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