Jidoka
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Toyota Production
System (TPS)
“All About the People”
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Goal of TPS
• Cost reduction
• Improvement of
productivity
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Technical Elements of
TPS
•
•
•
•
•
•
•
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Kanban
Just-in-time
Small lot delivery
Jidoka or quality in the process
Heijunka or leveling of demand
Visual control
5S or clean, orderly worksites
Focus on Jidoka
Automation with “human”
intelligence
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Jidoka’s Purpose
• Increase quality
• Lower costs
• Improve customer
relations
• Shorten delivery time
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What does Jidoka do?
• Adds human judgment to
automated equipment
• Minimizes poor quality
• Makes the process more
dependable
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Founder of Jidoka
Taiichi Ohno
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Eliminate Waste
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Production System
Two Structural
Features
• Just-in-time
• Jidoka
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Developed Due to:
• Overproduction
• Wasted time at the machine
• Waste in the transportation
units
• Waste in processing
• Waste in inventory
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Jidoka Gives the
Employee
• Responsibility
• Authority to stop
production
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Employee Responsibility
• Help solve problems
• To make decisions that affect
them
• Be accountable for their work
• Improve productivity
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Daily Activities
•
•
•
•
Working in dangerous operations
Physical labor
Repetitive labor
Continually rotating jobs
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Stopping
Production
• Quality is assured
• Costs are reduced
• Eliminates
problems
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Prevention Techniques
• Poka-yoke
• Andons
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Poka-yoke
Used for
– visual control of quality
– to prevent defects from
happening
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Andons
• Red - line stoppage
• Yellow - call for help
• Green - normal operation
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When Andons Go Off
• Assembly line is stopped
• Management is summoned
– supervisors
– maintenance personnel
– engineers
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Other Visual Controls
• Kanbans
• Standard operation
sheets
• Process control charts
• Tool boards
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Problems Recorded
• Easels
• Worksheets
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Daily Exercises
• Time is reserved to go over problems
• Work on solving the problems for
future quality
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Example of Jidoka
Toyota power loom
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Problem
• Shuttlecocks would stick
• Created defects in cloth being
produced
• Produced unacceptable quality
• Costs increased
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Solution
• Developed a stopper
• Turned automation
into atonomation
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End Result
• Reliable system
• Cheaper to operate
• Improved quality
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Objectives of Jidoka
• Ensure top quality
• Prevent equipment
breakdowns
• Better use of manpower
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Jidoka’s Ultimate Goal
Quality
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Readings List
Automotive Manufacturing & Production, July 2001,
v113 i7 p64.
Doing Business in and with Japan. New York:
American Management
Association, Inc., 1969.
Economist, 10/17/92, Vol. 325 Issue 7781, Survey of
car industry, p5.
Hay, Edward J. The Just-In-Time Breakthrough. Rath
& Strong, Inc.: John Wiley & Sons, Inc., 1988.
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Continued Reading List
The Financial Times, December 13, 2001, p13.
Imai, Masaaki. Kaizen. New York: McGraw-Hill,
Kaizen Institute, 1986.
Industrial Management & Data Systems, July-August
1997 v97 n7-8 o274(6).
Management Review, June 1997, v86 i6 p36.
Sepehri, Mehran. Just-In-Time, Not Just In Japan.
American Production & Inventory Control Society,
Inc., 1986.
Togo, Yukiyasu & Wartman, William. Against All Odds.
New York: St. Martin’s Press, 1993.
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