Knowledge Co-Creation

Program
(Group & Region Focus)

GENERAL INFORMATION ON

KNOW-HOW OF MONOZUKURI AT JAPANESE

MANUFACTURING SITE
-PRODUCTIVITY IMPROVEMENT AND
FACILITY MAINTENANCE MANAGEMENT-
課題別研修 「日本的モノづくり現場のノウハウ－生産性向上と設備管理－」
JFY 2017
NO. J1704310 / ID. 1784844
Course Period in Japan: From October 22, 2017 to December 7, 2017

This information pertains to one of the JICA Knowledge Co-Creation Program (Group &
Region Focus) of the Japan International Cooperation Agency (JICA), which shall be
implemented as part of the Official Development Assistance of the Government of
Japan based on bilateral agreement between both Governments.
‘JICA Knowledge Co-Creation Program (KCCP)’ as a New Start
In the Development Cooperation Charter which was released from the Japanese
Cabinet on February 2015, it is clearly pointed out that “In its development
cooperation, Japan has maintained the spirit of jointly creating things that suit partner
countries while respecting ownership, intentions and intrinsic characteristics of the
country concerned based on a field-oriented approach through dialogue and
collaboration. It has also maintained the approach of building reciprocal relationships
with developing countries in which both sides learn from each other and grow and
develop together.” We believe that this ‘Knowledge Co-Creation Program’ will serve
as a center of mutual learning process.
I. Concept

Background
People of developing countries and emerging nations seek for knowledge concerning Japan
Brand, and the principles and the methodologies of quality control and production
improvement for manufacturing (Monozukuri) which have been systematized in the long
history of Japan. JICA has also promoted vitalization of private enterprises and local
businesses through human resource development in the industries and upgrading the
industrial technologies. To develop supporting industries and enhance the competitiveness
of small and medium-sized enterprises are some of the most crucial development issues at
emerging nations and developing countries and it is also anticipated that they would
contribute to the Japanese businesses in their nations where many Japanese companies
especially manufacturing industries move into

For what?
In order to improve the productivity of manufacturing companies, this training course aims to
develop human resources responsible for dissemination of quality control, productivity
improvement and facility maintenance management that are accustomed in Japan.

For whom?
This program is offered to 1) Skill dissemination officers of manufacturing industrial
association and 2) Governmental officials in charge of promotion of manufacturing.

How?
With a view to realizing productivity improvement, it is important to have not only specific
manufacturing skills but also a holistic production system by effectively coordinating
respective technologies. A manufacturing industry’s strength can be measured by the prices,
the qualities and the delivery time of their products. The business organizations’ activities
are to improve the abovementioned indices which lead to the reinforcement of their
competitiveness. The participants will learn quality control, productivity improvement
measures, stable operation policies and facility maintenance management from lectures,
practices and site observations at more than ten companies.

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II. Description

1. Title (J-No.): Know-how of MONOZUKURI at Japanese Manufacturing Site

-Productivity Improvement and Facility Maintenance Management- (J1704310)

2. Course Period in JAPAN: October 22, 2017 to December 7, 2017

3. Target Regions or Countries:

Brazil, Colombia, Djibouti, Mexico, Myanmar, Nigeria, Philippines, Tunisia and
Zambia

4. Eligible / Target Organization

This program is designed for
1) Skill dissemination officers of manufacturing industrial association
2) Governmental officials in charge of promotion of manufacturing in the
manufacturing sector

* 1) and 2) must have more than five years of experience in the above mentioned
fields.
* Counterparts or persons involved in JICA projects or working with JICA Senior
Volunteers and/or Advisors who satisfy the required qualifications are encouraged
to apply.

5. Course Capacity (Upper limit of Participants): 10 participants

6. Language to be used in this program: English

7. Course Objective
Strategic plan for strengthening system and human development is formulated in
participants’ organization.

8. Overall Goal
Productivity improvement and Facility maintenance management are improved in
participants’ organizations and countries.

9. Expected Module Output and Contents

This program consists of the following components. Details on each component are
given below:

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 Expected Module
Subjects/Agendas Methodology
Output

To identify the issues in (1) Basic concepts of MONOZUKURI

the participants’ country (Manufacturing process)
and to recognize the (2) Productivity improvement by
role of their loss-elimination Lecture
organizations by (3) Quality management with rejection Field visit
understanding quality (4) Activities for improving manufacturing and Exercise
control and productivity site (5S, kaizen)
improvement measures (5) How to find weakness of manufacturing
in Japan site

To identify the issues in (6)Basic concepts of facility maintenance

the participants’ country (7) Technique and skill for preventive
and to recognize the maintenance
role of their (8) Case study of minimizing breakdowns Lecture
organizations by by facility improvement Field visit
understanding stable (9) Introduction of CDT: Condition and Exercise
operation policies and Diagnosis Technology
facility maintenance (10) Introduction of Training system for
management in Japan mechanical and electrical skills

To improve capacity of
formulating a strategic
plan for strengthening
(11) Guidance of identifying the issues Lecture,
system for productivity
(12) Guidance of Action plan elaboration Discussion
improvement and
(13) Job report and Action plan and
human resource
presentation Presentation
development in
participants’
organization

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III. Conditions and Procedures for Application

1. Expectations for the Participating Organizations

(1) This program is designed primarily for organizations that intend to address
specific issues or problems identified in their operation. Participating
organizations are expected to use the project for those specific purposes.
(2) This program is enriched with contents and facilitation schemes specially
developed in collaboration with relevant prominent organizations in Japan.
These special features enable the project to meet specific requirements of
applying organizations and effectively facilitate them toward solutions for the
issues and problems.

2. Nominee Qualifications
Applying Organizations are expected to select nominees who meet the following
qualifications.
(1) Essential Qualifications
1) Current Duties:
- Officers of chambers of commerce, private enterprises federations and
business unions for SMEs
- Officials of local governments and public institutions that support SMEs and
local industry development in the manufacturing sector

* Candidates must provide information about the status of SMEs and local
industry promotion in their regional areas using the Job Report form
(Annex-2)
* Counterparts or persons involved in JICA projects or working with JICA
Senior Volunteers and/or Advisors who satisfy the required qualifications are
encouraged to apply.

2) Experience in the relevant field: have more than 5 years’ work experience in
the field of local industry promotion
3) Educational background: be a university graduate or have the equivalent
academic background
4) Language: have a competent command of spoken and written English which
is equal to TOEFL iBT 100 or more (This workshop includes active
participation in discussions, which requires high competence of English ability.
Please attach an official certificate for English ability such as TOEFL, TOEIC
etc., if possible.)
5) Health: must be in good health, both physically and mentally, to participate in
the Program in Japan. Pregnant applicants are not recommended to apply
due to the potential risk of health and life issues of mother and fetus.

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 (2) Recommendable Qualifications
Age: between the ages of thirty (30) and fifty (50) years

3. Required Documents for Application

(1) Application Form: The Application Form is available at the JICA office (or the
Embassy of Japan).

(2) Photocopy of passport: to be submitted with the application form, if you

possess your passport which you will carry when entering Japan for this
program. If not, you are requested to submit its photocopy as soon as you
obtain it.
*Photocopy should include the followings:
Name, Date of birth, Nationality, Sex, Passport number and Expire date.

(3) Issue Analysis Sheet (IAS) & Job Report: to be submitted with the
application form. The documents should be completed in accordance with
descriptions of Annex-1 (Issue Analysis Sheet) and Annex-2 (Job Report). The
IAS is used for screening of participants. It is a tool that logically organizes
relationships between issues or problems which a nominee’s organization is
facing with and the subjects to be covered in the training program in Japan.

4. Procedure for Application and Selection

(1) Submitting the Application Documents
Closing date for applications: Please inquire to the JICA office (or the
Embassy of Japan).
(After receiving applications, the JICA office (or the Embassy of Japan) will send
them to the JICA Center in JAPAN by August 22, 2017.)

(2) Selection
After receiving the documents through proper channels from your government,
the JICA office (or the embassy of Japan) will conduct screenings, and then
forward the documents to the JICA Center in Japan. Selection will be made by
the JICA Center in consultation with concerned organizations in Japan. The
applying organization with the best intention to utilize the opportunity of this
program will be highly valued in the selection. Qualifications of applicants who
belong to the military or other military-related organizations and/or who are
enlisted in the military will be examined by the Government of Japan on a
case-by-case basis, consistent with the Development Cooperation Charter of
Japan, taking into consideration their duties, positions in the organization, and
other relevant information in a comprehensive manner.

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 (3) Notice of Acceptance
Notification of results will be made by the JICA office (or the Embassy of Japan)
not later than September 22, 2017.

5. Conditions for Attendance

(1) to strictly adhere to the program schedule.
(2) not to change the program topics.
(3) not to extend the period of stay in Japan.
(4) not to be accompanied by family members during the program.
(5) to return to home countries at the end of the program in accordance with the
travel schedule designated by JICA.
(6) to refrain from engaging in any political activities, or any form of employment for
profit or gain.
(7) to observe Japanese laws and ordinances. If there is any violation of said laws
and ordinances, participants may be required to return part or all of the training
expenditure depending on the severity of said violation.
(8) to observe the rules and regulations of the accommodation and not to change
the accommodation designated by JICA.

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IV. Administrative Arrangements

1. Organizer
(1) Name: JICA KYUSHU (Training Program Division)
(2) Contact: [email protected]

2. Travel to Japan
(1) Air Ticket:
The cost of a round-trip ticket between an international airport designated by
JICA and Japan will be borne by JICA.
(2) Travel Insurance:
Term of Insurance: From arrival to departure in Japan
The traveling time outside Japan shall not be covered.

3. Accommodation in Japan
JICA will arrange the following accommodations for the participants in Japan:
JICA Kyushu International Center (JICA KYUSHU /KIC)
Address: 2-2-1 Hirano, Yahata Higashi-ku, Kitakyushu-shi, Fukuoka,
805-8505 Japan
TEL:+81-93-671-6311 FAX: +81-93-671-0979
(81: country code for Japan, 93: area code)
http://www.jica.go.jp/english/contact/domestic/index.html

4. Expenses
The following expenses will be provided for the participants by JICA:
(1) Allowances for accommodation, living expenses, outfit and shipping
(2) Expenses for study tours (basically in the form of train tickets)
(3) Free medical care for participants who become ill after arriving in Japan (costs
related to pre-existing illness, pregnancy or dental treatment are not included.)
(4) Expenses for program implementation including materials
For more details, please see “III. ALLOWANCES” of the brochure for participants
titled “KENSHU-IN GUIDE BOOK,” which will be given before departure for
Japan.

5. Pre-departure Orientation
A pre-departure orientation will be held at the respective country’s JICA office (or
Japanese Embassy) to provide participants with details on travel to Japan,
conditions of the workshop and other matters.

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V. Other Information

1. Reports Presentation
(1) Job Report & Issue Analysis Sheet (IAS)
Accepted participants will make a presentation of his/her Job Report & IAS in up to
10 minutes, at the early stage of the training program in order to share knowledge
and background with other participants as well as the course leader and lecturers.
Visual materials such as Power Point and pictures may be helpful for your
presentation. When you use Power Point, it is preferable to a font size of more than
24 points and not to use pictures in the background.

(2) Action Plan

Accepted participants are required to formulate an action plan at the end of the
training program in Japan to show your ideas and plans, which you carry out after
return home, reflecting the knowledge and method acquired from the training. Each
participant will have 10 minutes for presentation.

2. Remarks
JICA training is implemented for the purpose of development of human resources
who will promote the advancement of the countries, but not for the enrichment of
individuals or private companies. Matters of a trade secret and patent techniques will
remain confidential and inaccessible during the training.

VI. ANNEX

1. Issue Analysis Sheet (Annex-1)

2. Job Report (Annex-2)
3. Tentative Training Schedule (Annex-3)

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Annex-1
Issue Analysis Sheet (IAS) Guidelines

1. What is IAS?
(1) IAS is a tool to logically organize relationships between issues and contents
of the training program in Japan.
(2) IAS will help the nominee to clarify his/her challenges to be covered in each
expected module output and to formulate solutions to them.
(3) The sheet is to be utilized as a logical process control sheet to draw up
improvement plans for the issues by filling out the sheet in phases from prior
to the nominee's arrival through to the end of the training.
(4) In addition, it is used for the course leader and lecturers to understand the
issues that each participant is confronting, and provide him/her with technical
advice, useful references and solutions through the training program in
Japan.

2. How to fill out IAS?

(1) Please describe the issues you (your organization) confronts in column “A:
Issues that you (your organization) confront(s)”
Prepare the separate rows for each problem; if necessary, please add new
rows.
(2) In column “B: Actions that you (your organization) are (is) taking”, please
describe actions that you (your organization) are taking to solve the issues
shown in column A.
This information is very important to carry out the training course and also to
make Action Plan as a fruit of the training.
(3) In order to solve issues, you (your organization) need various types of
information, so you hope to participate in this training course.
The main purpose of this training course is to provide the information you
need. The contents of this course are shown in Ⅱ-9 (Expected Module
Output and Contents on PP. 3)
Referring to the "List of Subjects" in this table, please extract subjects from
which you expect to get useful information you need, and write their Subject
No. in column “C: Subject No.”
You can input as many subjects as you think the subjects are related.
You do not need to input "Subject Titles" into the chart, but only "Subject No."

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Issue Analysis Sheet (IAS)
Name:
【A】 Issues that you (your organization) confront(s). No 【B】 Actions that you (your organization) are (is) taking. 【C】 Subject No.*)
１

*)
【C】 Please write the Subject No. you most expect to get the information you need.
Please refer the Number of Subjects/Agendas shown in the tables of this General Information (pp.3.)

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Annex-2

Know-how of MONOZUKURI at Japanese Manufacturing Site

Job Report
Name:
Country:
Organization and present post:
E-mail:

Remarks 1: The Report should be typewritten in English (12-point font, A4 size paper), and total
pages of the report should be limited to 3 pages.
Remarks 2: Each participant is required to have presentation in 10 minutes based on this Job
Report and IAS at the early stage of the training for the purpose of making the
training more effective and fruitful by comprehending the situations and problems of
the participants each other.

1. The current situation of manufacturing industries in your country or region

① GDP composition by industry
② Composition of the manufacturing industry by type of business

2. The national or local government policies

① Development policies for the manufacturing industry
② Supporting policies for the small and medium-sized manufacturing industry

3. What is/are the overall problem(s) of the manufacturing industry you belong to or
you exercise jurisdiction over?

4. What is your image of Japanese manufacturing industry and at what points do you
feel differences between your country’s manufacturing and that of Japan?

5. Do you already know and implement the items mentioned below?

Please place a check mark next to the each item accordingly.
I know being carried out
5S
KAIZEN
Autonomous maintenance
TQC
Muda Zero Activity
(waste elimination activity)
Condition diagnosis technology

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Annex-3
Tentative Training Schedule
Know-how of MONOZUKURI at Japanese Manufacturing Site
-Productivity Improvement and Facility Maintenance Management- in 2017
AM PM
Date
Subject Place Subject Place

Oct.22 Sun Arrival

23 Mon Program Orientation by JICA KIC -Same as the left- KIC

24 Tue General Orientation by JICA KIC -Same as the left- KIC

25 Wed Interchange program by JICA KIC Course guide by KITA KIC

26 Thu Problem solution method using IAS KIC Problem solution method using IAS KIC

27 Fri Basic concept of Monozukuri KIC Safety management at manufacturing sites KIC

28 Sat

29 Sun

30 Mon Introduction to maintenance management KIC Extraction of issues using IAS KIC
Observation at a maintenance shop of oil
31 Tue Introduction to maintenance management KIC Fukuda Oil Hydraulic Mfg. Co.
hydraulic equipment
Nov. 1 Wed Plant management improvement KIC Extraction of issues using IAS KIC
Observation at a maintenance shop of aircraft ANA Component Technics Co.,
2 Thu Kitakyushu → Nagasaki
parts and equipment Ltd.
3 Fri Nagasaki → Kitakyushu

4 Sat

5 Sun
Yawata Electric Machinery Mfg. Yawata Electric Machinery Mfg.
6 Mon Practical training on productivity diagnosis Practical training on productivity diagnosis
Co., Ltd. Co., Ltd.
7 Tue Job report presentation KIC Japanese manufacturing culture/ Review KIC

8 Wed Autonomous maintenance KIC Observation at Yaskawa robot plant Yaskawa Electric Corp.

9 Thu Practical training on autonomous maintenance Mitsubishi Chemical Corp. Practical training on autonomous maintenance Mitsubishi Chemical Corp.

10 Fri Iprovement of plant management KIC Iprovement of plant management KIC

11 Sat

12 Sun
Yawata Electric Machinery Mfg. Yawata Electric Machinery Mfg.
13 Mon Practical training on quality control at site Practical training on quality control at site
Co., Ltd. Co., Ltd.
14 Tue Visit to Nissan Motor Kyushu Factory Nissan Motor Kyushu Factory Discussion KIC

15 Wed Practical maintenance KIC Practical maintenance KIC

Support policies for small and medium-sized
16 Thu KIC Kitakyushu → Tokyo
enterprises
Observation of three factories at an industrial
17 Fri Ota city, small factory area Observation at Toshiba Science Museum Toshiba Science Museum
complex of small-sized manufacturers
18 Sat

19 Sun Tokyo → Kyoto

20 Mon How to promote mechanization Hini Arata Kan Demo Center Observation of various automation equipment Hini Arata Kan Demo Center

21 Tue Move to Osaka General production management system Creation Core Higashi Osaka

22 Wed 5S training and plant observation Hiraoka Hyper Tools Inc. Observation of Monozukuri education Monozukuri Experience Center

23 Thu Himeji → Kitakyushu

24 Fri Introduction to equipment diagnosis KIC Practical training on equipment diagnosis KIC

25 Sat

26 Sun

27 Mon Skill training system Sankyu Research and Create Action plan guidance KIC

28 Tue Hands-on experience of Monozukuri Kitakyushu Innovation Gallery Hands-on experience of Monozukuri Kitakyushu Innovation Gallery
Japan casting & Forging
29 Wed Visit to Japan casting & Forging Corporation Discussion KIC
Corporation
30 Thu Observation of cell manufacturing system Takagi Co., Ltd. Action plan guidance KIC

Dec. 1 Fri Japan's maintenance management at site KIC How to find out weaknesses of factories/ Review KIC

2 Sat (Submission of the action plan)

3 Sun

4 Mon How to find out weaknesses of factories KIC Visit to TOTO (Residential equipment) TOTO Kokura No1 Plant

5 Tue Visit to Nishiraku Dairy industry Nishiraku Dairy industry Lecture of Sanwa Press Co. (management creed) Sanwa Press Co.

6 Wed Evaluation meeting KIC Action plan presentation KIC

7 Thu Departure from Japan

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 For Your Reference

JICA and Capacity Development

The key concept underpinning JICA operations since its establishment in 1974 has been the
conviction that “capacity development” is central to the socioeconomic development of any country,
regardless of the specific operational scheme one may be undertaking, i.e. expert assignments, development
projects, development study projects, training programs, JOCV programs, etc.
Within this wide range of programs, Training Programs have long occupied an important place in
JICA operations. Conducted in Japan, they provide partner countries with opportunities to acquire practical
knowledge accumulated in Japanese society. Participants dispatched by partner countries might find useful
knowledge and re-create their own knowledge for enhancement of their own capacity or that of the
organization and society to which they belong.
About 460 pre-organized programs cover a wide range of professional fields, ranging from
education, health, infrastructure, energy, trade and finance, to agriculture, rural development, gender
mainstreaming, and environmental protection. A variety of programs and are being customized to address
the specific needs of different target organizations, such as policy-making organizations, service provision
organizations, as well as research and academic institutions. Some programs are organized to target a
certain group of countries with similar developmental challenges.

Japanese Development Experience

Japan was the first non-Western country to successfully modernize its society and industrialize its
economy. At the core of this process, which started more than 140 years ago, was the “adopt and adapt”
concept by which a wide range of appropriate skills and knowledge have been imported from developed
countries; these skills and knowledge have been adapted and/or improved using local skills, knowledge and
initiatives. They finally became internalized in Japanese society to suit its local needs and conditions.
From engineering technology to production management methods, most of the know-how that
has enabled Japan to become what it is today has emanated from this “adoption and adaptation” process,
which, of course, has been accompanied by countless failures and errors behind the success stories. We
presume that such experiences, both successful and unsuccessful, will be useful to our partners who are
trying to address the challenges currently faced by developing countries.
However, it is rather challenging to share with our partners this whole body of Japan’s
developmental experience. This difficulty has to do, in part, with the challenge of explaining a body of
“tacit knowledge,” a type of knowledge that cannot fully be expressed in words or numbers. Adding to this
difficulty are the social and cultural systems of Japan that vastly differ from those of other Western
industrialized countries, and hence still remain unfamiliar to many partner countries. Simply stated, coming
to Japan might be one way of overcoming such a cultural gap.
JICA, therefore, would like to invite as many leaders of partner countries as possible to come and
visit us, to mingle with the Japanese people, and witness the advantages as well as the disadvantages of
Japanese systems, so that integration of their findings might help them reach their developmental
objectives.
 CORRESPONDENCE
For enquiries and further information, please contact the JICA office or the
Embassy of Japan. Further, address correspondence to:

JICA Kyushu International Center (JICA KYUSHU)

Address: 2-2-1, Hirano, Yahata Higashiku, Kitakyushu-shi,
Fukuoka 805-8505, Japan
TEL: +81-93-671-6311 FAX: +81-93-671-0979