JIDOKA

Mac Hu

What Will Be Covered

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

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
( )
( )
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 NUMMIs 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 highproduction, 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.