For any manufacturer, building a high-performance production system means balancing automation with human intelligence. It’s not just about doing things faster – it’s about doing them better, more consistently, and with less waste. This is the essence of Jidoka, a core principle of the Toyota Production System (TPS), and a methodology FactorySmart strongly endorses and integrates into our factory optimisation approach.
Here’s why Jidoka is so powerful – and how it can transform your factory floor, your team, and your output.
Jidoka – automation with a human touch
The term “Jidoka” refers to automation that empowers people. Unlike traditional automation systems that blindly continue despite defects or errors, Jidoka teaches machines and systems to detect irregularities and stop automatically. This pause allows human operators to fix the issue immediately – eliminating root causes and improving quality at the source.
This concept dates back to Sakichi Toyoda, founder of the Toyota Group. His mother, who worked long hours weaving on a manual loom, inspired him to design an automatic loom that stopped when a thread broke. Not only did this reduce waste and improve efficiency, it protected the dignity and energy of human work.
From this simple insight, the foundation of one of the world’s most efficient production systems was born.
Why stopping production can drive progress
It may seem counterintuitive, but stopping production when there’s a problem is one of the smartest things a factory can do. Here’s why:
- It prevents small issues from becoming major defects
- It builds quality into the process rather than inspecting for it afterward
- It empowers staff to solve problems instead of ignoring them
- It creates a culture of accountability and continuous improvement
In fact, Toyota’s production lines stop over 1,000 times per day – yet they consistently lead global vehicle production. Even during the height of the COVID-19 pandemic in 2020, Toyota produced 15% of all global passenger vehicles. That’s the power of building quality into your system from the start.
Jidoka and 2 Second Lean – aligned in purpose
At FactorySmart, we see strong parallels between Jidoka and the 2 Second Lean philosophy. Both are focused on eliminating waste, empowering people, and making small improvements every day that lead to big results.
While Jidoka enables machines to pause when needed, 2 Second Lean equips people to notice and fix the issues that cause those pauses in the first place. Together, they create a powerful, people-centred approach to smart manufacturing – where machines and humans work together to improve efficiency, quality, and morale.
Creating a culture of problem solvers
Jidoka does more than reduce defects – it transforms how people think.
By integrating Jidoka into your operations, you begin to:
- Build problem-solving into the process itself
- Reduce dependency on after-the-fact inspections
- Encourage employees to take ownership and engage more meaningfully
- Free up time for staff to upskill, learn, and innovate
And most importantly – Jidoka does not replace people. It elevates them. It gives your team space to focus on higher-value work and become co-creators of quality, not just machine minders.
This is automation done right
Make Jidoka work for your factory
You don’t need to be Toyota to apply the principles of Jidoka. Whether you’re a small manufacturer or a growing operation, this approach can bring immediate value by:
- Reducing waste and rework
- Shortening feedback loops
- Increasing team accountability
- Improving process visibility and stability
At FactorySmart, we help businesses take practical steps to implement Jidoka as part of their automation and optimisation journey. We don’t just bring in machines – we help you build a smarter system.
Want to see Jidoka in action?
Watch this quick explainer from Toyota: Watch video
Or take a look at Paul Akers’ 2 Second Lean mindset here: Watch video
Let’s help you unlock the same value
If you’re looking to reduce defects, improve quality, and build a factory culture where your team is empowered to solve problems daily, Jidoka is the place to start.
- Contact Ludwig, our CEO, for a personal conversation
- Visit our website to explore our optimisation and automation offerings
- Download our brochures for tools to implement Jidoka and 2 Second Lean in your own business
At FactorySmart, we’re not just selling systems – we’re building a future where factories run smarter, people feel valued, and quality is built from the inside out.