1. JIDOKA
Mac Hu

2. 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

3. What Will Be Covered Real World Examples Exercises Summary
Reading, References, Info Lists

4. What is Jidoka? Automation with a human touch
Practice of stopping a manual line or process when something goes amiss
Also known as Autonomation
Jidoka, as practiced at Toyota, has several meanings. It may mean "automation with a human touch". Jidoka also refers to the practice of stopping a manual line or process when something goes amiss.
Jidoka (quality in station, or Autonomation) means to make equipment or processes that are “smart” enough to detect an undesired, abnormal state and stop so as not to produce a defective product.

5. 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
Jidoka also has a sub-title, "Quality built-in to the process". This seems to mean that the process inputs are controlled, and operators have authority to make adjustments within certain (control) limits.
The principle was first used by Sakichi Toyoda at the beginning of the 20th century when he invented a loom which stopped when the thread broke.
Taiichi Ohno considered Jidoka one of the two pillars of the Toyota Production System (TPS).

6. Role of Jidoka
Autonomation is an important component of Lean Manufacturing Strategy for high-production, low- variety operations, particularly where product life cycles are measured in years or decades.
Autonomation is an important component of Lean Manufacturing Strategy for high-production, low- variety operations, particularly where product life cycles are measured in years or decades. In high-variety, low-volume situations, the time and effort required is prohibitive. This is another example of how lean principles must be tailored to each situation.

7. 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
Jidoka involves the automatic detection of errors or defects during production. When a defect is detected the halting of the production forces immediate attention to the problem. The halting causes slowed production but it is believed that this helps to detect a problem earlier and avoids the spread of bad practices.
Autonomation transfers a level of human intelligence to automated machinery.

8. How Your Organization Can Benefit From Jidoka
No defective products produced
Tremendous improvement in productivity
Since the machine stopped when a problem arose, no defective products were produced. This meant that a single operator could be put in charge of numerous machines, resulting in a tremendous improvement in productivity.

9. 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
The term jidoka used in the TPS can be defined as "automation with a human touch." The word jidoka traces its roots to the automatic loom invented by Sakichi Toyoda, Founder of the Toyota Group. The automatic loom is a machine that spins thread for cloth and weaves textiles automatically. In the olden days, back-strap looms, ground looms, and high-warp looms were used to manually weave cloth. In 1896, Sakichi Toyoda invented Japan's first self-powered loom called the "Toyoda Power Loom." Subsequently, he incorporated numerous revolutionary inventions into his looms, including the weft-breakage automatic stopping device, which automatically stopped the loom when a thread breakage was detected, the warp supply device, and the automatic shuttle changer. Then, in 1924, Sakichi invented the world's first automatic loom, called the "Type-G Toyoda Automatic Loom (with non-stop shuttle-change motion)" which could change shuttles without stopping operation. The Toyota term "jido" is applied to a machine with a built-in device for making judgments, whereas the regular Japanese term "jido" (automation) is simply applied to a machine that moves on its own. Jidoka refers to "automation with a human touch," as opposed to a machine that simply moves under the monitoring and supervision of an operator.

10. A Closer Look at Jidoka -- Concept
Concept of Jidoka, by Toyota Motor Corporation, describes the improvement in daily workflow.

11. 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
The original meaning of Jidoka was "Automation" just as in English. It was written in Kanji as shown. The Kamigo Engine Plant developed many stoppage devices to halt automated machines. This became the word "Autonomation". It was pronounced as Jidoka but the Kanji had a subtle difference-- the addition of a few strokes representing humans or people.
Automation is focused on labor reduction. Autonomation (Jidoka) is focused on quality improvement, and the independence of the man from the process. Automation increases technicality, Autonomation reduces technicality. This allows skill levels to be lower in similar processes when comparing East to West. Another cost reducer!

12. 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
Jidoka consists of a number of tasks involving exercising human judgement It can refer to equipment automatically stopping when there’s a problem.
At Toyota, all machines are set up with automatic stop machines. When the machine stops, the entire process shuts down.

13. 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
Mr. Tomo Harada, 35 years with Toyota Motor Corporation in a variety of management positions

14. 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.)
Production System Statement, NUMMI (New United Motor Manufacturing, Inc.)

15. Exercises Q1: What is Jidoka?
Q2: How would your organization benefit from implementing Jidoka?
Q3: What is the role of Jidoka?
Answer 1: Jidoka, known as “Autonomation” means "automation with a human touch". Jidoka also refers to the practice of stopping a manual line or process when something goes amiss.
Answer 2: Jidoka involves the automatic detection of errors or defects during production. When a defect is detected the halting of the production forces immediate attention to the problem. The halting causes slowed production but it is believed that this helps to detect a problem earlier and avoids the spread of bad practices. Autonomation transfers a level of human intelligence to automated machinery.
Answer 3: Autonomation is an important component of Lean Manufacturing Strategy for high-production, low- variety operations, particularly where product life cycles are measured in years or decades.

16. 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.

17. 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.

18. Reading List & References
Strategos, Inc.
Toyota Motor Corporation
FredHarriman.com – Kaizen Basics
Art of Lean, Inc.
Strategos, Inc. is a consulting company, focusing on improving business and manufacturing operations. It provides a variety of training material online, including articles, audiovisuals, and training lessons.
FredHarriman.com – Kaizen Basics is a personal website, designed for people who are interested in Kaizen. The resources offered there are chosen for 2 main reasons, either they help further the implementation of kaizen, or they relate in some way to translating and interpreting for kaizen activities.
Art of Lean is also a consulting firm, offering a variety of custom training options. Its website was established to provide the ever growing audience of lean practitioners with some fundamental materials related to the Toyota Production System.

19. Reading List & References
New United Motor Manufacturing, Inc.
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.
New United Motor Manufacturing, Inc.(NUMMI) is the pioneering joint venture of General Motors Corporation and Toyota Motor Corporation. Established in Fremont, California, in 1984, NUMMI helped change the automobile industry by introducing the Toyota Production System and a teamwork-based working environment to the United States.

20. 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.