The Toyota Production System (TPS) is a manufacturing methodology developed by Toyota that focuses on eliminating waste, improving quality, and increasing efficiency. TPS incorporates principles like Just-In-Time (producing only what is needed when it is needed) and JIDOKA (automation with a human touch). This system has been widely adopted and adapted by other industries worldwide. 

The Toyota Production System (TPS) has its roots in the concept of serving others. The story behind TPS is fascinating and demonstrates the values on which it and the idea of Jidoka were founded. 

Jidoka Has its Roots in Automation and Human Intelligence

2 Second Lean is a powerful business approach which FactorySmart endorses. The concept of 2 Second Lean is inspired by the Toyota Production System (TPS), which focuses on eliminating waste and making production more efficient and profitable. Jidoka is a crucial pillar of TPS’s Lean success and is best described as ‘Adding the Human Touch to Automation.’

The Jidoka concept can be traced back to Sakichi Toyoda, the founder of the Toyota Group, who invented the automatic loom to lessen his mother’s workload. 

Toyoda’s mother worked into the early morning hours, producing goods on a manual loom. Not only was this physically taxing, but mistakes slowed down the process, and wasted material lessened the profits she made from her hard labour. 

In his endeavour to contribute and mechanise the manual loom, Toyoda added integrated decision-making abilities to the machine, significantly enhancing productivity and work efficiency. This was the inception of the Jidoka concept.

What Exactly is Jidoka and What Makes it Transformational?

The basic philosophy of the Toyota Production System is centred around two key pillars. The first is Jidoka, loosely translated as “automation with a human touch.” This concept entails stopping production immediately when irregularities are detected. This prevents defective products by correcting problems at the source instead of continuing production and risking a chain reaction with far more significant consequences further down the line. 

Stopping mid-process may seem counterproductive, but it isn’t. This ingenious concept eliminates the outflow of sub-standard products while making it possible to build quality into processes. Human interception at this point facilitates problem solving and correcting an issue at the point of impact.

Interestingly, the TPS production line stops on average 1000 times per day, yet Toyota produced 15% of all passenger vehicles each day in 2020 (the highest production rate of all vehicle manufacturers) at the height of the COVID-19 pandemic. Consider the impact that COVID-19 had on the workforce in general, and this staggering statistic demonstrates the power of Jidoka. 

Importantly, DO NOT underrate the value of human interaction. Even though putting Jidoka into practice may require fewer machine minders, it allows you to free your workforce up to upskill and become empowered to find solutions to problems. Jidoka, just like the 2 Second Lean principle, creates a culture of problem solvers. 

Toyota has perfected the Jidoka function and has sophisticated processes to trigger Jidoka. Take a look at the Toyota way of setting Jodoka in action. https://www.youtube.com/watch?v=TUKpxjAftnk

Take Action

While Jidoka is vital to Toyota’s success, it is as powerful in any manufacturing process. In fact, real life situations benefit just as much in any business environment. Here is Paul Akers’ 2 Second Lean journey: https://www.youtube.com/watch?v=aUtCbI5tmTc&t=2s

Follow us to discover more of Toyota’s winning concepts, or contact Ludwig, FactorySmart’s CEO, to learn how to implement Jidoka and 2 Second Lean in your business.