Toyota's Stunning Advancements in Producing Yakitori Grills!
**Toyota's Kaizen Approach Transforms Yakitori Production**
In a surprising yet fruitful collaboration, Toyota Motor East Japan (TMEJ) has partnered with Akitahinaiya, a producer of locally-bred Hinai chicken in Odate, Akita Prefecture, to apply Toyota's renowned Kaizen approach in a non-automotive industry. This groundbreaking initiative, launched in 2013, has seen significant improvements in efficiency and productivity, particularly in the production of negima yakitori, grilled chicken skewers with scallions.
The journey began when Akio Toyoda, then-President of Toyota, made a decision in 2011 to support the Tohoku region's recovery by helping manufacturing take permanent root there. TMEJ was born as a result of this decision in 2012. The collaboration with Akitahinaiya was one of the many initiatives TMEJ launched to achieve this goal.
The first step in the transformation was the implementation of the 5S's, the foundational pillars of Kaizen. The storeroom at Akitahinaiya, which was initially disorganized and lacked a logical layout, with items used only during the December busy period given priority, was reorganized. This reorganization, guided by the 5S's - Sort, Set in Order, Shine, Standardize, and Sustain, significantly reduced the time spent searching for items and improved workflow.
The team also focused on streamlining production processes, analyzing workflows and implementing changes to eliminate unnecessary steps. This resulted in a dramatic reduction in production time, with the time taken to make negima yakitori slashed by 93%. The first mouthful of meat on negima yakitori is made bigger for a more enjoyable texture, and the bottom pieces of the skewers are smaller to ensure even cooking.
Collaboration and respect for people are key principles of Kaizen. By engaging with local staff and involving them in the improvement process, the team built trust and fostered a collaborative environment. This collaboration was crucial in identifying areas for improvement and implementing effective changes.
Yukimi Mutou, Representative Director of Akitahinaiya, was initially "shocked" to discover 64 complaints from employees. However, she was pleased that everyone had spoken up to create a better workplace. The complaints were posted up on a wall and taken down once resolved, following the method used at Toyota's production plants.
The success of this initiative has not gone unnoticed. 157 companies are currently involved in this programme, including Akitahinaiya. Another Akita specialty, kiritanpo, was sampled during the visit. The principles of continuous improvement and waste elimination, central to Toyota's Kaizen approach, are proving to be effective in various workplaces beyond manufacturing.
In a world where efficiency and productivity are paramount, Toyota's Kaizen approach can significantly improve efficiency in non-automotive industries. The example of yakitori production in Akitahinaiya demonstrates how these principles can be applied effectively, transforming workflows and improving overall performance.
- The principles of Toyota's Kaizen approach, initially applied in the automotive industry, are now being utilized in the finance sector by companies seeking to enhance their operational efficiency.
- The technology industry is also embracing the Kaizen philosophy, with businesses adopting its continuous improvement and waste elimination strategies to streamline their transportation logistics and reduce costs.
- Moreover, the business community is recognizing the potential of Toyota's Kaizen approach in diversifying industries, such as the food industry, where it could significantly boost productivity, as evidenced by the transformation in yakitori production at Akitahinaiya.
