Toyota's Remarkable Strides in Crafting Yakitori Grills
In the heart of Akita Prefecture, a remarkable transformation is taking place. Toyota Motor East Japan (TMEJ), a division of the renowned automotive giant, has ventured into uncharted territory, collaborating with a local chicken producer named Akitahinaiya. This unique partnership, born in 2012, is a testament to Toyota's commitment to helping manufacturing take permanent root in the Tohoku region following the 2011 Great East Japan Earthquake.
The focus of this collaboration is on two traditional Akita specialties: negima yakitori (grilled chicken skewers with scallions) and kiritanpo (mashed rice on skewers). TMEJ's mission was to streamline the production process of these delicacies, starting with the chaotic storeroom at Akitahinaiya.
Prior to TMEJ's intervention, the storeroom was a maze of disorganization, with items used only during the December busy period given priority. The TMEJ team, armed with the 5S's methodology—Sort, Set in Order, Shine, Standardize, and Sustain—set about organizing and cleaning the storeroom. This reorganization not only made the space more efficient but also reduced the time employees spent searching for tools and materials, resulting in a smoother workflow.
The improvements didn't stop at the storeroom. TMEJ's team then turned their attention to the negima yakitori production process itself. Using time measurements and close observation, they identified inefficiencies and implemented continuous improvements. This meticulous approach led to a staggering 93% reduction in the time needed to make negima yakitori.
The impact of these improvements extends beyond the food industry. Many of the key points from these efforts can be useful in various workplaces beyond manufacturing. Yoshinari Kudou, Project General Manager, emphasized the importance of gaining acceptance from employees before making improvements. He noted that the initial apprehension felt by the genba staff, who were constantly monitored with a stopwatch during the kaizen process, was soon alleviated as they began to see the benefits of the changes.
In 2013, TMEJ launched an initiative that allows companies from different industries to learn about their kaizen efforts and gain insights for themselves. Akitahinaiya was one of the first companies to participate in this programme, gathering concerns from their approximately 20 employees as the first step in this evaluation process. The submitted problems were then addressed using the 5S's method, one of TMEJ's kaizen pillars.
Currently, 157 companies are involved in this initiative, demonstrating the far-reaching impact of Toyota's kaizen approach. Representative Director Mutou was surprised to discover that her employees had raised 64 concerns, highlighting the potential for improvement in even the most seemingly efficient workplaces.
As Toyota continues to apply its kaizen principles to various industries, it's clear that the transformative power of this approach is not limited to the automotive sector. The collaboration between Toyota and Akitahinaiya serves as a shining example of how these principles can be applied to enhance efficiency and productivity in diverse industries, from food production to manufacturing and beyond.
[1] Source: Toyota Motor East Japan (TMEJ) internal reports.
- The unique partnership between Toyota Motor East Japan (TMEJ) and Akitahinaiya, a local chicken producer, has demonstrated that the principles of Toyota's kaizen approach can be applied beyond the automotive industry, extending to industries such as food production.
- The 5S's methodology—Sort, Set in Order, Shine, Standardize, and Sustain—used by TMEJ in their collaboration with Akitahinaiya, can be useful in various workplaces, promoting productivity and efficiency.
- The improvements made by Toyota in the manufacturing process of traditional Akita delicacies like negima yakitori and kiritanpo, have not only boosted productivity but also provided valuable insights for other businesses, especially in the areas of personal growth, education and self-development, and finance.
- The collaboration between Toyota and Akitahinaiya has shown that technology can be leveraged to streamline business operations, benefiting not only the manufacturing industry but also other sectors such as finance, business, and technology.
