Embarking on a Lean Japan Tour is more than just a professional excursion—it’s an immersion into the birthplace of the Toyota Production System (TPS). This experience offers unparalleled insights into Lean principles, operational excellence, and the cultural philosophy that drives one of the world’s most efficient manufacturing systems. For Lean practitioners, business leaders, and process improvement specialists, the Lean Japan Tour provides the rare opportunity to witness firsthand the intricate mechanics of world-class production. The Center for Lean Excellence organizes this Lean Japan Tour, ensuring participants gain a comprehensive understanding of Toyota’s methodologies.
Day 1 | Arrival & Orientation
Warm Welcome in Japan: First Impressions of Nagoya
As participants touch down in Nagoya, Japan’s automotive hub, they are welcomed into a world where precision, respect, and efficiency define every aspect of life. The city’s modern yet deeply traditional aura sets the stage for the Lean Japan Tour ahead.
The Essence of Japanese Hospitality (Omotenashi)
Japanese hospitality, or Omotenashi, is deeply ingrained in both culture and business. This principle of selfless service ensures that guests feel valued, setting the tone for the days ahead.
Traditional Japanese Tea Ceremony: A Lesson in Mindfulness and Respect
The Lean Japan Tour begins not with machinery but with mindfulness. The tea ceremony, a centuries-old tradition, embodies patience, discipline, and respect—qualities essential to TPS. Observing this ritual helps participants appreciate the meticulous attention to detail that defines Japanese craftsmanship.
Cultural Immersion and Setting Expectations for the Tour
A comprehensive orientation introduces participants to Japanese etiquette, business culture, and the rigorous schedule ahead. This session ensures that visitors not only observe TPS but also experience its underlying philosophies.
Day 2 | Workshop 1 – The Obeya Experience
Introduction to Obeya: The Nerve Center of Lean Decision-Making
The concept of Obeya—which translates to “big room”—is where Toyota’s leaders make strategic decisions through visual management. This central hub facilitates communication, ensuring alignment across all functions.
How Obeya Fosters Cross-Functional Collaboration
Unlike traditional boardrooms, Obeya walls are covered in key performance indicators, project timelines, and real-time metrics. This openness fosters transparency and collaboration, reducing inefficiencies in decision-making.
Hands-On Application of Visual Management Techniques
Participants engage in practical exercises, learning to translate data into actionable insights using Toyota’s visual management methods. These techniques can revolutionize decision-making in any organization.
Learning from Mr. Matsudaira: A Masterclass in Lean Leadership
A distinguished Lean expert, Mr. Matsudaira, shares his extensive experience in implementing Obeya in Toyota and beyond. His lessons provide an in-depth understanding of how leadership can drive continuous improvement.
Day 3 | Workshop 2 – Toyota Cost Management
Understanding Toyota’s Cost Philosophy: Beyond Cutting Expenses
Toyota’s cost management isn’t about aggressive cost-cutting; it’s about maximizing value while maintaining quality. The focus is on sustainable efficiencies rather than short-term financial gains.
Value Engineering and Cost Reduction Without Compromising Quality
The principles of Genchi Genbutsu (go and see) and Muda elimination help Toyota engineers identify waste without sacrificing quality. This approach ensures that every yen spent contributes to product excellence.
The Role of Kaizen in Financial Efficiency
Continuous improvement, or Kaizen, plays a crucial role in cost management. By refining processes daily, Toyota minimizes financial waste while enhancing efficiency.
Workshop Insights from Mr. Toshio Horikiri: Mastering Cost Discipline
Renowned cost management specialist Mr. Toshio Horikiri shares insider knowledge on Toyota’s financial strategies, demonstrating how businesses can adopt similar approaches.
Day 4 | Toyota Tier 2 Supplier Visit & Toyota Museum
Exploring AVEX: The Backbone of Toyota’s Precision Engineering
A visit to AVEX, a Tier 2 supplier specializing in brake, transmission, and engine parts, showcases how Toyota ensures superior component quality through its rigorous supplier standards.
How Toyota’s Supplier Network Ensures Seamless Integration
Toyota’s Just-In-Time (JIT) system depends on a tightly knit supplier network that operates with synchronized efficiency. Visitors on the Lean Japan Tour witness firsthand how Tier 2 suppliers contribute to this seamless integration.
Visit to Toyota Museum: A Journey Through the Evolution of Automotive Innovation
The Toyota Museum offers an inspiring look into the evolution of Toyota, from its humble beginnings as a textile company to its global dominance in automotive manufacturing.
Key Takeaways from Toyota’s History and Continuous Improvement
Participants on the Lean Japan Tour gain a deeper understanding of how Toyota’s commitment to innovation and continuous improvement has shaped its legacy.
Day 5 | Toyota Tier 1 Supplier Visit & Journey to Tokyo
Inside Somic Ishikawa Inc: Excellence in Suspension Technology
A visit to Somic Ishikawa Inc., a Tier 1 supplier, highlights Toyota’s stringent quality requirements and the precision engineering behind its vehicles.
How Toyota Selects and Collaborates with Its Top-Tier Suppliers
Toyota’s supplier selection process emphasizes long-term partnerships, mutual trust, and shared commitment to excellence.
The Journey to Tokyo: Preparing for the Assembly Plant Experience
As participants travel to Tokyo, anticipation builds for the ultimate Lean Japan Tour experience—the Toyota Assembly Plant tour.
Day 6 | Toyota Assembly Plant – The Heart of TPS
Witnessing the Legendary Toyota Production System in Action
A factory visit brings to life key TPS concepts such as JIT manufacturing and Heijunka (production leveling).
The Art of Just-In-Time Manufacturing
Participants observe how Toyota maintains minimal inventory while ensuring parts arrive precisely when needed, reducing waste and maximizing efficiency.
Jidoka: The Philosophy of Built-In Quality
Toyota’s Jidoka principle empowers workers to halt production if defects are detected, preventing faulty products from advancing down the line.
Final Reflection and Certification Ceremony
A certification ceremony recognizes participants’ deepened understanding of TPS, equipping them to implement Lean principles in their organizations.
Day 7 | Departure – Taking Lean Lessons Home
The Center for Lean Excellence: Continuing the Lean Journey
For those eager to deepen their Lean knowledge, the Center for Lean Excellence offers continued training, ensuring that the spirit of TPS thrives globally.
Beyond the Factory: Lean Conversations Over Dinner
Traditional Japanese Dinner & Lean Networking
Beyond workshops and factory visits, the Lean Japan Tour fosters meaningful connections through a traditional Japanese dinner. In this informal setting, participants engage with Lean experts, exchanging insights on operational challenges and real-world applications. This reflects Nemawashi—the Japanese practice of building trust and consensus. Over authentic cuisine, attendees strengthen professional relationships and deepen their understanding of the collaborative spirit behind the Toyota Production System.
Bringing Lean Lessons to Life
The Lean Japan Tour is more than just an exploration of the Toyota Production System—it’s an immersive experience that blends hands-on learning, cultural insights, and professional networking. From factory floors to traditional dinner tables, every moment reinforces the principles of efficiency, respect, and continuous improvement. Participants leave not only with a deeper understanding of Lean but also with valuable connections and practical strategies to implement in their own organizations.
