2. “Everyone is a genius at least once a year; a
real genius has his original ideas closer
together.”
- Georg Lichtenberg
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3. Toyota Production System (TPS)
TPS
Single Piece
Flow Poka Yoke
Jidoka
People
JIT
Pull Involve-
ment Andons
Takt Time
Heijunka
Sequencing Leveling
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4. Jidoka
Automation with a human touch = Autonomation
Origin of Jidoka - Type G
Toyoda Automatic Loom
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5. What is Jidoka ?
The Japanese word for “autonomation”
Toyota Motor defines the word as, “investing machines with human
intelligence.”
Can be used with machines or people
One of the two main pillars of TPS (Toyota Production Systems)
Machines are designed to stop automatically when a problem is
detected or any operator on the line, has the power to stop
production
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6. Why use Jidoka ?
Lower costs
Increase quality
Reduce lead time
Improve customer service
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7. Ninbennoaru Jidoka
Alerts the worker, when a defective item is
produced or a machine malfunction has
occurred
This allows the problem to be dealt with immediately,
preventing the production and passing of defects
Problems and the defects they cause, can be more
quickly localised, isolated, and corrected
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8. Prevention Techniques
Poka Yoke
Visual control of quality
Prevents defects from happening
Andons
Light to signal production line status / attention
• Red: line stopped
• Yellow: call for help
• Green: all normal
Pin-Pan-Pon
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9. Jidoka Process
Poka Yoke Devices
Investigate the
Fix or correct
Detect the root cause and
Stop the immediate
abnormality install counter-
condition measures
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10. “Try to learn something about everything
and everything about something.”
- Thomas Henry Huxley
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