Toyota Brings Innovation in the Production of Yakitori Skewers!
In the picturesque Odate, Akita Prefecture, a surprising collaboration is taking place between Toyota Motor East Japan (TMEJ) and a local chicken producer, Akitahinaiya. This unique partnership, born out of Toyota's commitment to aid the Tohoku region's recovery after the Great East Japan Earthquake in 2011, is revolutionising the production of negima yakitori.
Akitahinaiya, a renowned yakitori producer, joined TMEJ's programme in 2013, which aimed to educate companies from diverse industries about Toyota’s kaizen (continuous improvement) methods. Under the guidance of TMEJ, Akitahinaiya's leader, Yukimi Mutou, adopted a Toyota-inspired approach to address employee concerns, leading to a significant transformation in their workplace and production environment.
The transformation began with the gathering of 64 concerns from the approximately 20 employees at Akitahinaiya. These concerns were then displayed publicly and systematically addressed, a hallmark of Toyota’s kaizen style. This approach led to a 93% reduction in the time taken to make negima yakitori, bringing Toyota's manufacturing philosophy into traditional food production.
TMEJ's first kaizen pillar, the 5S's (Sort, Set in Order, Shine, Standardize, and Sustain), played a crucial role in this transformation. TMEJ's team worked with Akitahinaiya employees to organise the storeroom, resulting in a smoother workflow. This decision, which led to the birth of Toyota Motor East Japan in 2012, has had far-reaching effects, with many of the key points from the improvements proving useful in various workplaces beyond manufacturing.
The leader of Akitahinaiya, Yukimi Mutou, was "shocked" by the results of the initiative. Representative Director Mutou admitted to holding onto unnecessary items in the storeroom and not having a clear layout. The first mouthful of negima yakitori is now made bigger to provide a more enjoyable texture, while the bottom pieces are smaller to ensure even cooking for harder-to-grill areas.
Yoshinari Kudou, Project General Manager at TMEJ, emphasised the importance of gaining acceptance from the genba (workplace) staff before suggesting improvements. The bottom line is that TMEJ's kaizen efforts have helped Akitahinaiya enhance its yakitori production by adopting proven Toyota manufacturing and workplace improvement practices.
[1] For more information, please refer to Toyota's official website or Akitahinaiya's official website.
[1] The collaboration between Toyota Motor East Japan (TMEJ) and a small business named Akitahinaiya in the food-and-drink industry has resulted in a significant transformation in their business operations and production, particularly in the production of negima yakitori.
[2] This transformation was made possible through TMEJ's kaizen (continuous improvement) methods, which Akitahinaiya's leader, Yukimi Mutou, learned as part of TMEJ's educational programme in 2013.
[3] By adopting Toyota's 5S's (Sort, Set in Order, Shine, Standardize, and Sustain) and other manufacturing practices, Akitahinaiya saw a 93% reduction in the time taken to make negima yakitori, showcasing the versatility of these practices beyond the automotive industry.
[4] This sought-after small business, located in Odate, Akita Prefecture, has now enhanced the texture and cooking process of their negima yakitori, making it a more enjoyable dining experience for customers.
[5] TMEJ's project has demonstrated the potential for technology and business principles from the manufacturing industry to impact a diverse range of small businesses, including those in the food-and-drink and lifestyle sectors.
