JIDOKA
Mac Hu
What Will Be Covered
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What is Jidoka?
Role of Jidoka
How your firm can benefit from Jidoka
A closer look at Jidoka
How it works
What Will Be Covered
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Real World Examples
Exercises
Summary
Reading, References, Info Lists
What is Jidoka?
• Automation with a human touch
• Practice of stopping a manual line or process
when something goes amiss
• Also known as Autonomation
What is Jidoka?
• Quality built-in to the process
• First used by Sakichi Toyoda at the
beginning of the 20th century
• A pillar of the Toyota Production System
Role of Jidoka
• Autonomation is an important component
of Lean Manufacturing Strategy for highproduction, low- variety operations,
particularly where product life cycles are
measured in years or decades.
How Your Organization Can
Benefit From Jidoka
• Jidoka helps to detect a problem earlier
• Jidoka avoids the spread of bad practices
• A level of human intelligence is transferred
into automated machinery
How Your Organization Can
Benefit From Jidoka
• No defective products produced
• Tremendous improvement in productivity
A Closer Look at Jidoka –
manufacturing high quality products
• The word traces its roots to the automatic loom
invented by the founder of the Toyota Group
• A built-in device for making judgments
• Opposed to a machine that simply moves under the
monitoring and supervision of an operator
A Closer Look at Jidoka -- Concept
A Closer Look at Jidoka—
”Autonomation” clarification
• Automation vs. Autonomation
(自動化)
(自働化)
• Labor Reduction vs. Quality Improvement
• Increases technicality vs. Reduces technicality
How It Works
• Adds human judgment to automated equipment
• Minimizes poor quality
• Makes the process more dependable
• Gives the employee responsibility and authority
to stop production
In The Real World
“If Jidoka is not practiced then you can
not attain a very high level quality and
productivity will suffer since you are
not catching problems.”
Mr. Tomo Harada, 35 years with Toyota Motor
Corporation in a variety of management positions
In The Real World
“One of NUMMI’s basic concepts is
that quality should be ensured in the
production process itself. This concept,
known as Jidoka, means not allowing
problems to pass from one work station
to the next.”
Production System Statement, NUMMI (New
United Motor Manufacturing, Inc.)
Exercises
Q1: What is Jidoka?
Q2: How would your organization benefit
from implementing Jidoka?
Q3: What is the role of Jidoka?
SUMMARY
• Jidoka, also known as “Autonomation”,
means automation with a human touch.
• Jidoka, first used by Sakichi Toyoda, the
founder of Toyota, is one of two pillars of
the Toyota Production System.
• Jidoka is an important component of Lean
Manufacturing Strategy for high-production,
low- variety operations.
SUMMARY
• Jidoka helps to detect a problem earlier and
avoids the spread of bad practices.
• Jidoka results in high-quality products and
makes improvement in productivity.
• Autonomation is different from automation.
Reading List & References
• Strategos, Inc.
http://www.strategosinc.com/
• Toyota Motor Corporation
http://www.toyota.co.jp/
• FredHarriman.com – Kaizen Basics
http://www.fredharriman.com/
• Art of Lean, Inc.
http://artoflean.com/
Reading List & References
• New United Motor Manufacturing, Inc.
http://www.nummi.com/
• MONDEN, YASUHIRO, Toyota Production
System, Third Edition, Industrial
Engineering & Management Press, Atlanta,
Georgia, USA, 1998.
• OHNO, TAIICHI, Toyota Production
System- Beyond Large Scale Production,
Productivity Press, 1988.
For More Information
• Automotive Manufacturing & Production, July 2001, v113
i7 p64.
• The Financial Times, December 13, 2001, p13. Imai,
Masaaki. Kaizen. New York: McGraw-Hill, Kaizen
Institute, 1986.
• The Just-In-Time Breakthrough. Rath & Strong, Inc.: John
Wiley & Sons, Inc., 1988.
• Management Review, June 1997, v86 i6 p36. Sepehri,
Mehran. Just-In-Time, Not Just In Japan. American
Production & Inventory Control Society, Inc., 1986.