The Continuous

Improvement Academy

TOYOTA
PRODUCTION
SYSTEM
- JIDOKA -

Jidoka refers to the capability of humans or machines to

identify an anomaly in materials, machinery, or processes
and intervene to prevent the anomaly from propagating to
subsequent stages.

Source: TPS Basic Handbook, Art of Lean, Inc.

 The Continuous
Improvement Academy

TOYOTA PRODUCTION SYSTEM

 The Continuous
Improvement Academy

INTRODUCTION
Conventional methods involve inspecting
finished parts and products before
customer delivery.
Yet, the guarantee of defect-free items is
not absolute when relying solely on
inspector sampling.
Offline inspection by inspectors adds
minimal value, prompting the need to
innovate processes that reduce the
reliance on inspectors and emphasize
manufacturing products of superior
quality.
Essentially, the objective is to "build quality
into the product."

Source: TPS Basic Handbook, Art of Lean, Inc.

 The Continuous
Improvement Academy

JIDOKA ESSENTIALS
Building in Quality

This principle mandates that team

members diligently evaluate quality at
every work stage to prevent the
propagation of defects to subsequent
phases.

Each team member should

acknowledge that the downstream
process functions as a customer and
should never transfer a faulty product.

If equipment malfunctions, it should be

automatically detected and stopped to
prevent further issues. Mistake-proofing
devices are commonly employed for
this task.
Source: TPS Basic Handbook, Art of Lean, Inc.
 The Continuous
Improvement Academy

JIDOKA ESSENTIALS
Building in Quality

If a quality defect arises, we can identify

its root cause and implement corrective
measures to prevent its reoccurrence.

Source: TPS Basic Handbook, Art of Lean, Inc.

 The Continuous
Improvement Academy

JIDOKA ESSENTIALS
Inspection Work

Inspection work entails more than

simply assessing whether components
or completed products meet quality
standards.

Defects can be minimized by

thoroughly understanding root causes
and implementing targeted
countermeasures based on a
comprehensive analysis.

Therefore, the aim of inspection work is not

merely to identify defective products but to
eliminate the root causes of defects.

Source: TPS Basic Handbook, Art of Lean, Inc.

 The Continuous
Improvement Academy

JIDOKA ESSENTIALS
Repair Reduction

It is crucial to acknowledge that repair work

necessitates additional manpower, diminishes
added value rates, and elevates production
costs.

Therefore, activities of this nature should be

identified and prioritized for elimination.

Source: TPS Basic Handbook, Art of Lean, Inc.

 The Continuous
Improvement Academy

JIDOKA ESSENTIALS
Human Work and Machine Work

Human work entails tasks that necessitate

team member engagement to be
accomplished. Examples include handling parts,
loading and unloading machinery, activating
machine cycles through palm buttons, and
executing manual operations.

In contrast, machine work denotes the

segment of tasks that machinery executes
automatically, independent of operator
intervention.

Source: TPS Basic Handbook, Art of Lean, Inc.

 The Continuous
Improvement Academy

JIDOKA ESSENTIALS
Human Work and Machine Work

By employing "smart" machines

and equipment capable of
detecting, signaling, and
identifying anomalies, there is no
longer a necessity to allocate a
team member solely for
continuous process monitoring.

This segregation of human tasks

from machine operations
provides the agility required to
adapt to fluctuations in customer
requirements.

Source: TPS Basic Handbook, Art of Lean, Inc.

 The Continuous
Improvement Academy

JIDOKA ESSENTIALS
Standardization

Consistency in methodology
plays a pivotal role in minimizing
process variations and enhancing
production efficiency within a
specified timeframe.

Within the production area, two

essential documents often
displayed are the Standardized
Work Chart and Quality Check
Sheets.

Source: TPS Basic Handbook, Art of Lean, Inc.

 The Continuous
Improvement Academy

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TPS Foundations
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integrating the power of the 7
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Toyota Production System

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In this course, We provide an in- The Toyota Way
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TPS Foundations
Production System (TPS), through a
detailed explanation from TPS Pillars (JIT&Jidoka)
authentic sources. Q,C&D at the GEMBA

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