Factory Warrior: Episode 9 "First Business Trip"
Best Practices at Steelworks
In the Manufacturing Improvement Department where Toshio worked, he felt the strong winds of change within the company even while being chased by daily tasks. With the merger of Sanyu Metal Industry and Yamato Steel, there was an urgent need for information exchange within the company. In particular, the term "best practice" became a buzzword, and movements to learn from each other's strengths between different steelworks became active.
The Manufacturing Improvement Department analyzed equipment specifications, staffing levels, and productivity at each steelworks to determine where the strengths lay. Toshio was in charge of the heavy plate mill, while Kuwata looked after the ironmaking plant, Horie the steelmaking plant, Kuma the sheet metal plant, and Onoda the logistics plant.
Among them, the heavy plate mill at the Nagasaki Steelworks in Kyushu was known as the "demon of rationalization." It boasted high productivity with a small number of personnel and was a model for other steelworks.
The heavy plate mill at the Kamisu Steelworks, where Toshio worked, was by no means bad, but it was said that the Nagasaki Steelworks was a cut above in terms of productivity and equipment efficiency. Within the company, there was a growing movement to use the rationalization methods and production systems of the Nagasaki Steelworks as a reference, and Toshio was also exchanging information with the Nagasaki Steelworks as part of this effort.
However, remote meetings were not yet widespread in this era, and using video conferencing required dedicated equipment. Furthermore, this system required reservations and was inconvenient, often suffering from connection drops. At the Kamisu Steelworks where Toshio worked, landline phones were still the mainstream, and information exchange did not proceed smoothly.
After talking with the person in charge in Nagasaki several times over the phone and through video conferences, both sides began to feel frustrated by the inefficiency. One day, the person in charge in Nagasaki suggested, "Why don't you come here once and see the entire heavy plate mill?"
Toshio was a little hesitant, but he decided to go on the business trip, thinking that he should be able to gain a lot of information by actually seeing the equipment. This was his first business trip, and he waited for the day with a mix of anticipation and nervousness.
He immediately consulted his boss, Hashiba, who readily agreed, saying, "That's a good idea. You should definitely go."
On the day of the business trip, Toshio headed to Nagasaki on an early morning flight. On the way from the airport to the Nagasaki Steelworks by taxi, the scenery visible from the window was fresh, and white smoke was rising from the chimneys of the steelworks visible in the distance.
"So this is the Nagasaki Steelworks..." Toshio got out of the taxi and looked up at the vast steelworks, feeling once again how much responsibility he was carrying.
At the Nagasaki Steelworks, the person in charge he had spoken with in advance welcomed Toshio. That person was his peer, Fuwa. At the reunion after a long time, the two naturally smiled.
"Toshio, welcome to Nagasaki. Let's go see the heavy plate mill right away." Fuwa said cheerfully, and the two headed to the factory.
The heavy plate mill at the Nagasaki Steelworks was famous for its thorough rationalization. It was operated efficiently with a small number of personnel, and a production system that eliminated waste as much as possible was in place.
"So this is the Nagasaki heavy plate mill... It's amazing, Fuwa." Toshio was wide-eyed and impressed by the scale of the factory and its precise operation.
Fuwa continued his explanation proudly. "We are always conscious of rationalization. For example, in this process, where three people are usually needed, we run it with two. Of course, we don't compromise on quality either."
At those words, Toshio felt even more surprised. Although the Kamisu Steelworks was also promoting rationalization, he had never seen such thorough efficiency.
"If this could be done in Kamisu too..." Toshio thought to himself, but at the same time, he felt that there was still room for improvement in his own factory.
A Night in Nagasaki
After the factory tour, a drinking party hosted by Komuro, the department manager of the Nagasaki Steelworks, began. Komuro was a stout man who had played rugby at Sawada University, and Toshio was overwhelmed by his presence.
As the drinking party progressed, Toshio was stunned by Komuro's remarks.
"Rationalization? You can just talk to the president of the partner company and say, 'You're going to rationalize by 5% this year, so thanks in advance!' and that's it, hahaha."
Toshio's eyes widened in surprise at those words. At the Kamisu Steel Works, discussions on rationalization are handled carefully, and coordination with partner companies takes time. In contrast, decisions here were quick and powerful, but also felt somewhat heavy-handed.
"Is this the Nagasaki way...? The culture is completely different." Toshio muttered to himself.
The drinking party continued, and they moved on to a second venue, a drag bar. Even there, Komuro's presence stood out remarkably.
"Sato, you're from Keiyo University, right? Sing your alma mater!" Komuro took the microphone and handed it to Toshio.
However, Toshio couldn't immediately recall the school song. His mind had gone blank from tension and fatigue.
"I-I'm sorry, the lyrics are..." Toshio replied, bewildered.
Komuro laughed loudly, teased him by asking, "Did you really graduate?", and then took the microphone back himself.
"Alright, I'll sing it for you! This is how you sing it, remember this!"
Komuro began to sing the Keiyo University school song with great confidence. The shop instantly livened up at his powerful singing voice, and while Toshio was overwhelmed by the atmosphere, he couldn't help but be impressed by Komuro's imposing figure.
That night, on the way back to the hotel, Toshio walked with Fuwa and reflected on the events of the drinking party.
"Nagasaki is completely different, Fuwa. You're doing well here." Toshio expressed his honest impressions.
Fuwa replied with a laugh, "No, once you get used to it, this is normal. You'll get used to it too, Toshio."
"But still, the way things are done here is amazing. I was a bit overwhelmed." Toshio expressed his genuine admiration.
"Well, it's tough here too, you know. But you're doing a solid job at Kamisu, right?" Fuwa said encouragingly.
Toshio felt encouraged by those words, but also felt that he still had much to learn.
Back at the Kamisu Steel Works, Toshio decided to apply the knowledge and experience he gained from this business trip to his future work with even more enthusiasm. He vowed not to spare any effort in his daily work so that one day he, too, could become someone who could stand tall with pride.