Thank you gentlemen.
The IJN had 63 submarines on 7 Dec 1941, around 12 of them operated off the US West Coast in Dec 1941 sinking IIRC 3 merchant ships and damaging 2.
The Japanese actually increased their tanker capacity in 1942, and not just through the capture of Allied tonnage. But their shipbuilding industry was never going to succeed it delivering enough tonnage when the major part of their oil imports in the run up to WW2 was being carried to Japan on US owned vessels. Even less so after the Allies started targeting tankers specifically from late 1943.
As for getting the oil back to Japan, your statement misses two important points that meant a large part didn't need to go back to Japan.
1. Japanese tankers were able to haul oil from the DEI oilfields and refineries direct to the major fleet bases at Truk & Rabaul until late 1943 / early 1944.
2. In Jan 1944 the IJN moved a significant proportion of its fleet down to the Singapore area to be near its oil supplies. (That move caused a panic amongst the Allies who worried about a repeat of Operation C and saw major movements of ships and aircraft to the theatre and around Australia). It was from bases in the DEI that large elements of the IJN fleet sailed ahead of the Battle of Philippine Sea in June 1944 and Leyte Gulf in Oct. They also moved a substantial part of their pilot training down to the DEI to be near the fuel supplies.
Both these things helped reduce the demand for tanker tonnage.
My suggestions were what could the Japanese navy have
planned differently in 1936-39 rather than going the Yamato route. My list was not large and there were many other possibilities. We are also using hindsight

My suggestion for the subs was based on hindsight and is part of knowing that the Japanese 12 (?) subs off the west coast did so little. Imagine a dozen German type IXs operating off the West coast for several weeks in Dec 1941? Supplies/reinforcements to Pearl Harbor and further east would have been at a near standstill, coastal trade on west coast would also have been much reduced. Major shifts of escort ships (and ASW aircraft) from the Atlantic to the Pacific would have been taking place for several month in early 1942.
The US did shift a lot of forces as it was, but if the Japanese had sunk 12-15 ships and damaged another 4-6 in 2-3 weeks? And if the Japanese had sent 6-8 boats back in Feb-March or April of 1942? Japanese subs didn't do a whole lot (much of anything?)for stopping supplies/reinforcements reach Pearl Harbor in 1942 or 1943 either. Or for things reaching Australia. I know that was not the Japanese role for subs but that is doctrine/training and not the boats themselves (although they were less than ideal for commerce raiding).
Anticipating the needed oil transport needs of 1942 and later in 1936-38 would have been hard. Idea was that the Japanese navy would push back the enemy leaving the transports unmolested. We know that didn't happen from 1943 on but who
knew in pre-war years. If somebody is looking for an easy answer to what to do instead of the Yamato class then more tankers is an easy answer.
Japanese had 21-22 years to study submarine warfare of WW I and over two years to study the Battle of the Atlantic. Yes they had ordered some escorts but in sort of prototype quantities (plans could sit on the self until needed?). One or more were overly complicated. Japanese DDs and escorts were woefully short of sensors and even numbers of depth charges. for an Island nation that relied on imports of many things this was a major failing. Japanese escort commanders were considered 2nd rate. Not by their enemies here (although that too) but escort duty was sometimes seen as a demotion or dead end command. Some commanders had not gone to the Naval Academy but to the merchant marine academy. If there was a caste system in the RN against the "wavy navy" one can only imagine the regard that regular Japanese naval officers held the escort commanders in.
Japanese training in ASW was also rather sketchy regardless of which schools they went to.
As mentioned in a different thread the Japanese overclaimed sub kills at around a 9-10 ratio which also hindered even basic improvements to ASW capabilities. Not helped by most Japanese small ships being overweight/top heavy to being with. Just trying to put on an extra 12-18 depth charges seems to have a problem.
There were a number of other paths that the Japanese navy could have taken if one assumes that the Yamato was not a good idea. We can also look at the US battleships. What did many of the US battleships after North Carolina class accomplish aside from shore bombardment? Hindsight is a wonderful thing
