- Topics: [[Productivity]] - Source: https://www.youtube.com/watch?v=Q-8dnpiEePk --- A day in the life of a Japanese Knife maker working in knife factory in Seki City Japan. This is what a typical work day would be for a knife technician in the factory and outside of workplace. The Japanese work culture can be seen in her everyday activities. Also, this is how Japanese knives are made. Nene works as a knife technician at Zwilling J.A. Henckels Japan, originally a 291-year-old German Knife maker who eventually setup an office in Japan and later acquired their knife factory here in Seki city, also known in Japan as the city of blades, crafting flawless samurai swords and knives for more than 800 years and producing half of Japan’s total knives in this city alone. Today, 90% of the company’s knives sold in Japan are actually made here at this factory. Throughout her shift, she’s tasked with inspecting knives being crafted that day, to ensure that each knife meets the factory’s strict quality standards. Which also means that she’s responsible for knowing the details about each and every knife that’s crafted in the factory including the entire build process for that individual knife and the technical requirements each one must satisfy in order for her to fully perform the inspections. In fact, all the workers are required to undergo basic training when joining, and during the training period, each worker’s skills are assessed and based on their strengths, assigned a specific role such as sharpening knifes, welding, etc. Apparently, sharpening the knives by hand is one of the most challenging parts when crafting a knife. So much so, the factory itself only has 9 specialists who have mastered the skill, and at the moment only 2 who are skilled enough to perform Kiwami Honbazuke, the most extreme and technical knife sharpening possible. --- ![[Day in the Life of a Japanese Knife Maker 3-8 screenshot.png]] A rack of products. Knives. About half the knives have some thing protecting their tips. From a glance, it is uncertain the ordering of how these knives are placed. Also, from this photo, it appears that all knives are tagged with some thing. This makes sense. You need to know why the knife is there, who it belongs to, and what needs to be done for that particular knife. That should be documented in the label that stays with a knife always throughout the production cycle. ![[Day in the Life of a Japanese Knife Maker 3-11 screenshot.png]] The production manager, pulling out their prepared clipboard from the rack of paperwork. There are binders containing documents for the company. ![[Day in the Life of a Japanese Knife Maker 3-12 screenshot.png]] Production manager inspecting blue bins on racks. Each rack is labelled with some sort of identifier. The racks in this photo are immobile. They do not have wheels on their feet. ![[Day in the Life of a Japanese Knife Maker 3-13 screenshot.png]] Products and materials are placed in bins. Products are separated by thin sheets of foam with accompanying labels. Labels are color-coded, matching their associated bins. ![[Day in the Life of a Japanese Knife Maker 3-20 screenshot.png]] Workers are stationed. Some are surrounded by bins. All bins are on racks. Within sections, separated by the vivid yellow marker, we can see walkways or sections identified by blue markers on the ground. ![[Day in the Life of a Japanese Knife Maker 3-20 screenshot (1).png]] Switches and controls are neatly labelled ![[Day in the Life of a Japanese Knife Maker 3-25 screenshot.png]] Switches and controls are neatly labelled ![[Day in the Life of a Japanese Knife Maker 3-31 screenshot.png]] The production manager is holding a clipboard with some spreadsheet that she is filling out. In the background, we can see some sort of large progress board on what appears to be a very, very large whiteboard with a grid layout. ![[Day in the Life of a Japanese Knife Maker 3-37 screenshot.png]] The stairway of the factory. The walkway is very clearly indicated by the vivid yellow line marker that can be seen throughout the entire factory. This yellow line marker is similar to the ones used on roads for driving. Something to indicate that a user should not cross without caution. The stairway walkway is also split in half, designed for optimal traffic. You stay on the right hand side to go either up or down. You cannot cross. The directionality of travel is also indicated by arrows along the bottom of the stairway as well as the walls. Going down is indicated with red arrows. Going up is indicated with yellow arrows. ![[Day in the Life of a Japanese Knife Maker 3-39 screenshot.png]] Many bins can be seen in this photo. Most of them are green, which is different compared to the blue bin that the factory production manager is holding. On the right hand side, we can see another worker being surrounded by green bins. ![[Day in the Life of a Japanese Knife Maker 3-46 screenshot.png]] The production manager is updating some thing on their spreadsheet, attached to the clipboard. Also, in this photo, is a piece of documentation that is laminated and stuck on the side of a machine. Certain parts of this document is highlighted. One can assume, that this is documentation needed for operation of a machine close by. ![[Day in the Life of a Japanese Knife Maker 3-48 screenshot.png]] In this photo, we can see a large collection of what appears to be standardized, transport bins. They are neatly stacked and colour-coded onto what appears to be easy to move dollies. All of this is sectioned off by the vivid yellow line marker on the floor. Also in this photo, is a moveable tool cabinet, with elongated Allen, keys station at the top, and a collection of ratcheting wrenches neatly displayed on the side. ![[Day in the Life of a Japanese Knife Maker 3-51 screenshot.png]] The production manager always keeps their clipboard with them. In addition to them wearing their factory uniform, you can see that on the side of their hip, is some sort of pouch. Probably to hold tools that they need readily available. In this photo, they can be seen loading a bin onto a rack with the rolling mechanisms on the bottom.<div><br></div><div>It is very interesting to think about placing a bin on this rolling rack to simply transport it approximately 2 feet. This is one of those small design details to make work slightly more efficient. By having this rack, set up, it ensures that the bin moves to the correct location with minimal energy expenditure from the user.</div> ![[Day in the Life of a Japanese Knife Maker 3-54 screenshot.png]] The production manager is inspecting what looks to be a very makeshift panel for various instruments, charts, and tools. The most DIY container would be the small, empty container of gum, now used to hold writing instruments, such as pens and markers. This DIY panel also appears to has some electronics, such as buttons that controls some thing else. ![[Day in the Life of a Japanese Knife Maker 3-56 screenshot.png]] The sections of the factory are neatly enclosed in squares. The boundaries of the sections are denoted by a vivid yellow line. The operator on the left, place is bins on a rack that has roller bearings on the bottom. There's no doubt makes the bins, probably standard sized, easier to move from one location to another while on the rack. All visible racks in this photo have wheels. There's no doubt makes racks of various sizes and types. Easy to move from one location to the other. It is also safe to assume that these wheels can be locked. ![[Day in the Life of a Japanese Knife Maker 4-4 screenshot.png]] Woman is holding her transport bin. She seems to be in the admin area of the factory facility. On the shelf, you can see binders of documents, and other labelled bins of material. ![[Day in the Life of a Japanese Knife Maker 4-48 screenshot.png]] The factory production manager is transferring notes from their worksheet onto a notepad. ![[Day in the Life of a Japanese Knife Maker 4-58 screenshot.png]] Workers can be seen sharpening knives at their station. Very close to the station, is a wall of what appears to be large, sharpening stone discs required for this work. Beside each worker, is a standard been filled with ties they need to process. Behind the workers, is a large collection of bins on racks. ![[Day in the Life of a Japanese Knife Maker 5-5 screenshot.png]] Heat treatment process to harden the knives. Similar to other parts of the factory, the large machinery is surrounded by the vivid yellow line marking on the ground. This process is called Yakirire in Japanese. ![[Day in the Life of a Japanese Knife Maker 5-19 screenshot.png]] Frozen blades are taken out of a large freezer. Next to the lid of the freezer, Is a collection of binders. These binders look very old. Unsure is still in use. Right next to the binder, is a tray for various tools that the operator may need. This includes, a marker, two pens, a little notepad, and a Casio calculator. Given what we seen so far, it is safe to assume that all loose tools from pens to wrenches, should always be placed in either a tray or a pen. This keeps them organized, and makes it easier to transport. ![[Day in the Life of a Japanese Knife Maker 5-32 screenshot.png]] A mechanized assembly line takes heated and cooled knife blades into a heated furnace for them to be treated, therefore hardening the blades ![[Day in the Life of a Japanese Knife Maker 5-33 screenshot.png]] A wall of potentially con Bon cards. They are separated by days, which is represented by kanji characters. These characters are color-coded, along with their associated cards. It is unsure what each card contains. From what I can see, it looks like times. Are D noted on the cards. As well as temperature, possibly. ![[Day in the Life of a Japanese Knife Maker 5-34 screenshot.png]] The area for straightening. The area is enclosed and squared off by the vivid yellow line marker on the ground. There is a worker a station to brightly lit work area, surrounded by bins of blades. ![[Day in the Life of a Japanese Knife Maker 5-44 screenshot.png]] Worker is straightening the blade by hammering it. To the left-hand side of the worker, there is a rack that has what appears to be a spec sheet for blades. The process of straightening using this method is called "Hizumitori" in Japanese. ![[Day in the Life of a Japanese Knife Maker 5-50 screenshot.png]] Blades that that have been processed or placed in bins. A set of blades are arranged in a crisscross pattern. One can assume this is designed to maximize the amount of blades placed into the bin, while accounting for quick invisibility. ![[Day in the Life of a Japanese Knife Maker 5-51 screenshot.png]] Blades that that have been processed or placed in bins. A set of blades are arranged in a crisscross pattern. One can assume this is designed to maximize the amount of blades placed into the bin, while accounting for quick invisibility. ![[Day in the Life of a Japanese Knife Maker 6-5 screenshot.png]] Workers are assembling knives by hand. Beside each worker, is a rack for them to place the assembled knife blade down. This rock is designed in a way to very easily and quickly placed knives in them, also for a quick invisibility, for how many knives have been processed. On the backside wall, we can see some sort of board with either sticky notes or cards, arranged in columns. It is unknown what they are used for. ![[Day in the Life of a Japanese Knife Maker 6-39 screenshot.png]] A worker is buffing the handles of a knife in her station. The standardized blue bins are stacked on top of the standardized racks. Close to the buffing stations, are a collection of belts used for buffing. ![[Day in the Life of a Japanese Knife Maker 6-42 screenshot.png]] At 10 AM, all workers have a mandatory break. The factory provides 3 10 minute break sessions for workers throughout the day. Workers file from their stations single file down the lanes indicated by blue line markers on the ground. ![[Day in the Life of a Japanese Knife Maker 7-6 screenshot.png]] The laboratory of the factory. On the top shelf are a collection of binders. Underneath it, is a collection of laboratory equipment. For the machine on the left-hand side, labels can be seen above each of the controls and switches. ![[Day in the Life of a Japanese Knife Maker 8-0 screenshot.png]] Monthly improvement meeting presentation. Workers can be seen seated at a rectangular table, separated by plexiglass. The presentation is projected onto the wall. In the back, there is a large white board. Rough schematics can be seen at the very bottom. Above it, a table with what appears to be blade inches and dates and status. ![[Day in the Life of a Japanese Knife Maker 8-12 screenshot.png]] Representatives from each department Present their achievements, and what they can improve upon. ![[Day in the Life of a Japanese Knife Maker 8-36 screenshot.png]] Lunchtime. The factory provides bento boxes at a reasonable price. A bin for chopsticks and soy sauce are neatly presented next to what appears to be a common microwave. ![[Day in the Life of a Japanese Knife Maker 10-20 screenshot.png]] A collection of knivesAre nearly presented the door in the walls of the factory outlet/employee store. ![[Day in the Life of a Japanese Knife Maker 11-24 screenshot.png]] A model of a high-end knife can be seen in a CAD program. ![[Day in the Life of a Japanese Knife Maker 12-46 screenshot.png]] Finished / sharpened knives placed in a container submerged in solution. These knives are undergoing the process of "Kiwami Honbatsuke" - the most extreme and technical knife sharpening process. The process appears to be using water and large rotating whetstones. ![[Day in the Life of a Japanese Knife Maker 13-39 screenshot.png]] Finished knives are being inspected and cleaned. A worker is cleaning a knife at their station. The cubicle walls of the station is adorned with various tables and spreadsheets. ![[Day in the Life of a Japanese Knife Maker 13-52 screenshot.png]] A stack of finished knives are carefully layered on top of each other, separated by a thin sheet of foam. They are placed in the blue standardized bins. A sticky note with information is posted on the side of each of the bins. ![[Day in the Life of a Japanese Knife Maker 14-1 screenshot.png]] A warehouse looking room with rows of stacked cardboard boxes. These are most likely finished knives ready to be shipped to their designation. Above the stacks of boxes are signs indicating the destination of the boxes. The most prominent sign seen in this photo is for USA. ![[Day in the Life of a Japanese Knife Maker 14-11 screenshot.png]] Manual QA. Final inspection of each night before it is packaged. ![[Day in the Life of a Japanese Knife Maker 14-21 screenshot.png]] Stamp of approval. Japanese signature stamp. ![[Day in the Life of a Japanese Knife Maker 14-54 screenshot.png]] A stack of knives to be sharpened (or have been sharpened) with information forms. ![[Day in the Life of a Japanese Knife Maker 14-57 screenshot.png]] All tools and necessaries needed for this station, including a new sanding belt. They are transported using the standard blue bin. ![[Day in the Life of a Japanese Knife Maker 15-21 screenshot.png]] Entering today's inspection information and logs on a computer at the end of the work day.