Toyota Production

System
TPS Pillars | JIDOKA

Kaizen Made Easy

TPS Pillars
JIDOKA
Good to Know

Absence of any of the

three foundational
concepts (Heijunka,
Kaizen and
Standardization) will
definitely lead to lack of
sustainability and
maintenance of the
production system.
Trainer

Kaizen Made Easy

 TPS Pillars
JIDOKA
Good to Know

• Jidoka is one of the two pillars of the Toyota Production System. Absence of any of the
• It means providing machines and operators the ability to detect when an abnormal three foundational
concepts (Heijunka,
condition has occurred and immediately stop work. Kaizen and
• It only allows the production of one defect Standardization) will
definitely lead to lack of
• Jidoka highlights the causes of problems because work stops immediately when a sustainability and
problem first occurs. maintenance of the
production system.
• This leads to improvements in the processes that build in quality by eliminating the
root causes of defects. Trainer

Source: Lean.org
Kaizen Made Easy
 TPS Pillars
JIDOKA
Good to Know

• Jidoka sometimes is called autonomation, Absence of any of the

meaning automation with human three foundational
intelligence. concepts (Heijunka,
Kaizen and
• This is because it gives equipment the ability Standardization) will
to distinguish good parts from bad definitely lead to lack of
sustainability and
autonomously, without being monitored by maintenance of the
an operator. production system.
• This eliminates the need for operators to Trainer

continuously watch machines and leads in

turn to large productivity gains because one
operator can handle several machines, often
termed multiprocess handling.
Source: Lean.org
Kaizen Made Easy
 TPS Pillars
JIDOKA
Good to Know

• Once production stops due to any kind of Absence of any of the

abnormality, the operator must: three foundational
concepts (Heijunka,
1. Make an analysis of the defect Kaizen and
2. Act on the defect Standardization) will
definitely lead to lack of
3. Start with the production again sustainability and
maintenance of the
production system.
Trainer

Source: Coimbra, E. A. (2013). Kaizen in logistics and supply chains. McGraw-Hill Education.
Kaizen.com Kaizen Made Easy
 TPS Pillars
JIDOKA
Good to Know

• Three Key Concepts to effectively implement Jidoka Absence of any of the

three foundational
concepts (Heijunka,
Kaizen and
Standardization) will
definitely lead to lack of
sustainability and
maintenance of the
production system.
Trainer

Kaizen Made Easy

 TPS Pillars
JIDOKA
Good to Know

• Three Key Concepts to effectively Absence of any of the

implement Jidoka three foundational
concepts (Heijunka,
Kaizen and
Standardization) will
definitely lead to lack of
sustainability and
maintenance of the
production system.
Trainer

Kaizen Made Easy

 TPS Pillars
JIDOKA | Andon
Good to Know

• Andon is a visual management tool that Absence of any of the

highlights the status of operations in an area at three foundational
a single glance and that signals whenever an concepts (Heijunka,
abnormality occurs. Kaizen and
Standardization) will
• A typical andon, which is the Japanese term for definitely lead to lack of
“lamp,” is an overhead signboard with rows of sustainability and
numbers corresponding to workstations or maintenance of the
machines. A number lights when either: production system.
• a machine sensor detects a problem, which Trainer

automatically trips the appropriate light or

• an operator pulls a cord or pushes a button.
• The illuminated number summons a quick
response from the team leader.
Source: Lean.org
Kaizen Made Easy
 TPS Pillars
JIDOKA | Andon
Good to Know
Example from Toyota: Absence of any of the
• Anytime an operator notices that something is wrong (a part that does not fit correctly, for three foundational
example) (Photo 1), he pulls on the line-stop cord (Photo 2). concepts (Heijunka,
• That lights a visual signal and summons the team leader to go help the operator (Photo 3). Kaizen and
When the team leader arrives, the operator explains the problem. Standardization) will
• The team leader discovers a fitting that has slipped out of place (for example) and is able to definitely lead to lack of
resolve the problem (Photo 4). sustainability and
maintenance of the
production system.
Trainer

Source: Coimbra, E. A. (2013). Kaizen in logistics and supply chains. McGraw-Hill Education.
Kaizen.com Kaizen Made Easy
 TPS Pillars
JIDOKA | Andon
Good to Know

Andon Board Absence of any of the

• The andon board is a simple but highly-visible three foundational
concepts (Heijunka,
electronic sign displaying the status of Kaizen and
production lines. Standardization) will
• It notifies management immediately if a definitely lead to lack of
sustainability and
worker has identified a fault, precisely maintenance of the
identifying its location. production system.
• Workers take responsibility for production Trainer

quality, with the power to stop the production

line as required.
• The production line will not be restarted until
the reason for the fault has been resolved.

Source: Toyota.com
Kaizen Made Easy
 TPS Pillars
JIDOKA
Good to Know

• Three Key Concepts to effectively Absence of any of the

implement Jidoka three foundational
concepts (Heijunka,
Kaizen and
Standardization) will
definitely lead to lack of
sustainability and
maintenance of the
production system.
Trainer

Kaizen Made Easy

 TPS Pillars
JIDOKA | Poka-Yoke
Good to Know

• Poka-yoke is a Japanese term that means Absence of any of the

“error-proofing” by implementing simple three foundational
concepts (Heijunka,
and inexpensive devices that help Kaizen and
operators avoid mistakes in their work Standardization) will
definitely lead to lack of
caused by the wrong parts, leaving out a sustainability and
part, installing a part backwards, etc. maintenance of the
production system.
• In Japanese, “Poka” means inadvertent Trainer

error, and “yoke” means prevention.

• The purpose of poka-yoke is to achieve
100% quality by finding defects at their
source.
Source: Lean.org
Kaizen Made Easy
 TPS Pillars
JIDOKA | Poka-Yoke
Good to Know

• POKA YOKE CAN BE DEFINED IN 3 TYPES Absence of any of the

three foundational
concepts (Heijunka,
Kaizen and
Standardization) will
definitely lead to lack of
sustainability and
maintenance of the
Shutdown Control Warning production system.
When abnormalities The production of Signals abnormality or Trainer

occur, the operation errors is completely that errors are about

stops impossible to occur

Source: Coimbra, E. A. (2013). Kaizen in logistics and supply chains. McGraw-Hill Education.
Kaizen.com Kaizen Made Easy
 TPS Pillars
JIDOKA | Poka-Yoke
Good to Know

• POKA YOKE CAN BE CLASSIFIED ACCORDING TO SETTING Absence of any of the

FUNCTIONS three foundational
concepts (Heijunka,
• Contact: detects abnormalities in product shape or position by whether or not Kaizen and
contact was made with a sensing device Standardization) will
definitely lead to lack of
• Fixed-value: Abnormalities detected by checking for a specified number of motions sustainability and
or a specified operation parameter maintenance of the
• Motion-step: Abnormalities detected by checking for errors in actual motions that production system.
should be done according to some standard Trainer

Source: Coimbra, E. A. (2013). Kaizen in logistics and supply chains. McGraw-Hill Education.
Kaizen.com Kaizen Made Easy
 TPS Pillars
JIDOKA | Poka-Yoke
Good to Know

• Examples Absence of any of the

three foundational
concepts (Heijunka,
Kaizen and
Standardization) will
definitely lead to lack of
sustainability and
maintenance of the
production system.
Trainer

Kaizen Made Easy

TPS Pillars
JIDOKA | Conclusion
Good to Know

Absence of any of the

three foundational
concepts (Heijunka,
Kaizen and
Standardization) will
definitely lead to lack of
sustainability and
maintenance of the
production system.
Trainer

Kaizen Made Easy