Why is Toyota involved in expressway construction, and how exactly does "virtual Genchi Genbutsu" improve conditions for workers?
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Alongside greater motivation, those on the front lines also began to come up with suggestions for improvement.
akahiro Kanemaru, Project Director, Project Office, Obayashi JV
Rather than being told by us, I’m sure the site workers get more out of changing their own work practices. After incorporating the simulations, they have told us that work is noticeably smoother, and they are more motivated.
But of course, on a complex construction project, things don’t always proceed as simulated.
The workers sweating and toiling on site are not virtual avatars inside a simulator but flesh-and-blood human beings. Each has their own ways of working, honed through personal experience, and feels physically different from day to day.
The team realized that a dialogue with workers on the ground was crucial for improving simulation accuracy.
Noriaki Sakai, Assistant Manager, Infrastructure System Group No.2, Frontier Research Center
The workers have their own ideas about what works best, so if we tried to impose our way of doing things, we would definitely ruffle some feathers. That’s why it’s important to make everything visible so people can embrace the changes.
I’m fine with people telling us, “We can’t do that!” It allows us to ask why not and to incorporate their feedback.
We don’t think of the simulations as saying, “This is how you should work,” but rather as a communication tool. The key role in kaizen is played by those who use these tools.
It’s important for people with different ideas to talk and make improvements with a shared vision. Our role in these kaizen efforts is to identify the research that we need to do to achieve better results and to advance the technology.
Kanemaru notes that the simulations have sparked conversation in the genba.
Takahiro Kanemaru, Construction Supervisor, Obayashi JV
You can’t just come out and say, “You’re not doing it right.” (laughs)
Everyone is doing what they think is best based on personal experience. But once they see for themselves how the simulation can make work easier, things really get going.
The simulations are still under development with much work to be done, including the integration of many minor tasks. However, continued dialogue and feedback from the genba have helped the team iron out inconsistencies between the simulation and operations on the ground, while also highlighting areas of improvement.
GEN-VIR holds promise for use in wide-ranging scenarios, including high-rise building construction. Seeking to “connect mobility and infrastructure,” Toyota is pursuing further simulation-driven kaizen to improve conditions for hard-working people.