Jidoka: The Toyota Principle of Building Quality into the Process


Book Description

Jidoka is one of the main pillars of the TPS. The TPS is presented as a house with two pillars. One pillar represents just-in-time (JIT), and the other pillar the concept of Jidoka. Take away any of the pillars holding up the roof, and the entire system will collapse. Take out quality, and there is no TPS. Jidoka is a principle of building quality for customers—not inspecting quality. Building quality mean making it right the first time. If you are making defective products or using unacceptable quality standards and filtering these defects out through an inspection system, there is no building quality—and no Jidoka. You are just catching the mistakes made in the manufacturing process. This cost a lot of money and resources and puts the business at risk.




Jidoka


Book Description

Jidoka is one of the main pillars of the TPS. The TPS is presented as a house with two pillars. One pillar represents just-in-time (JIT), and the other pillar the concept of Jidoka. Take away any of the pillars holding up the roof, and the entire system will collapse. Take out quality, and there is no TPS. Jidoka is a principle of building quality for customers--not inspecting quality. Building quality mean making it right the first time. If you are making defective products or using unacceptable quality standards and filtering these defects out through an inspection system, there is no building quality--and no Jidoka. You are just catching the mistakes made in the manufacturing process. This cost a lot of money and resources and puts the business at risk.




The Toyota Way Fieldbook


Book Description

The Toyota Way Fieldbook is a companion to the international bestseller The Toyota Way. The Toyota Way Fieldbook builds on the philosophical aspects of Toyota's operating systems by detailing the concepts and providing practical examples for application that leaders need to bring Toyota's success-proven practices to life in any organization. The Toyota Way Fieldbook will help other companies learn from Toyota and develop systems that fit their unique cultures. The book begins with a review of the principles of the Toyota Way through the 4Ps model-Philosophy, Processes, People and Partners, and Problem Solving. Readers looking to learn from Toyota's lean systems will be provided with the inside knowledge they need to Define the companies purpose and develop a long-term philosophy Create value streams with connected flow, standardized work, and level production Build a culture to stop and fix problems Develop leaders who promote and support the system Find and develop exceptional people and partners Learn the meaning of true root cause problem solving Lead the change process and transform the total enterprise The depth of detail provided draws on the authors combined experience of coaching and supporting companies in lean transformation. Toyota experts at the Georgetown, Kentucky plant, formally trained David Meier in TPS. Combined with Jeff Liker's extensive study of Toyota and his insightful knowledge the authors have developed unique models and ideas to explain the true philosophies and principles of the Toyota Production System.




Toyota Production System Concepts


Book Description

Giving machines and operators the power to notice when something is wrong and quickly pause their work. This helps companies to increase quality at every step of the process and to have workers and machines work separately for better efficiency. Jidoka is a fundamental concept in the Toyota Production System, which is an important way of doing things in Toyota factories. It is one of the two main principles, along with just-in-time. Jidoka is a system that helps identify problems quickly because if a problem happens, work immediately stops. This helps make things better and prevents mistakes by fixing the main reasons for problems. Jidoka is sometimes referred to as autonomation, which means using automation along with human intelligence. This is because it allows machines to determine if parts are good or bad on their own, without needing someone to watch them. This means that operators don't have to constantly watch machines. This helps them to be more productive because one operator can control many machines at once. This is called multiprocess handling. The idea of jidoka started in the early 1900s when Sakichi Toyoda, who started the Toyota Group, made a machine that would stop on its own if a thread broke in a textile loom. In the past, when a thread would break on the loom, it would make a lot of bad fabric. So, someone had to watch each machine. Toyoda's invention allows one person to operate multiple machines. In Japanese, jidoka means automation, but it is a word created by Toyota that has additional meanings of being more humanistic and creating value.




Working with Machines


Book Description

How do companies in high labor cost countries manage to remain competitive? In western manufacturing, the more manual a process, the more severe the competitive handicap of high wages. Full automation would make labor costs irrelevant but remain impractical in most industries. Most successful manufacturing processes in advanced economies are neither fully manual nor fully automatic -- they involve interactions between small numbers of highly skilled people and machines that account for the bulk of the manufacturing costs and thereby remain competitive. In Working with Machines: The Nuts and Bolts of Lean Operations With Jidoka, author Michel Baudin explains how performance differences that can be observed from one factory to the next are due to the way people use the machines -- from the human interfaces of individual machines to the linking of machines into cells, the management of monuments and common services, automation, maintenance, and production control.




Welcome Problems, Find Success


Book Description

In this book, author Nate Furuta, former chair and CEO of Toyota Boshoku America Inc., shares the story of his decades of experience directly leading the establishment of Toyota cultures outside Japan. Furuta was the first Toyota employee on the ground at New United Motor Manufacturing Inc. (NUMMI), Toyota’s joint venture in California with General Motors, where he directly led the establishment of the most revolutionary labor-management agreement in the history of the US auto industry. In addition, Furuta was the first Toyota employee on the ground in Georgetown Kentucky at Toyota’s first full-scale, wholly owned manufacturing operation outside Japan, where he led (working directly with President Fujio Cho) the establishment of Toyota’s general management systems and culture there. This book tells the stories of establishing successful operations in those two iconic organizations as well as others. Furuta reveals details, both stories and process descriptions that only he can tell. He takes you along as he and others lead Toyota’s intense globalization from the early 1980s to recent days. He introduces you to the critical leaders in Toyota's history, such as Taiichi Ohno and Fujio Cho as well as Kenzo Tamai, the head of the company’s HRM function in the 1980s. This book is not about human-resource management (HRM) policies and procedures. It provides a deep dive into the way senior leaders embody deep awareness of HRM matters, developing and executing company strategy while at the same time developing organizational capability. The role of senior leaders isn’t just a matter of directing the company to achieve objectives; it is a matter of building the capability to achieve those objectives, consistently, and further developing capability as it executes. Key to this is to develop the awareness, attitude, capability, and practice of identifying problems as progress is made toward achieving objectives, which is, in fact, attained through steadily eliminating each problem as it arises. This becomes a self-reinforcing loop of the organization, tapping in to the essence of solving problems while simultaneously developing ever better problem-solving skills and better problem solvers. This loop propels an organization toward meeting its purpose while developing capability for capability development. Essentially, this book reveals Toyota’s general management systems from the firsthand experience of a Toyota Japanese senior manager and describes, with stories and process examples, the attitude, behaviors, and systems needed to successfully establish and lead in a true Lean business environment.




The Toyota Way


Book Description

How to speed up business processes, improve quality, and cut costs in any industry In factories around the world, Toyota consistently makes the highest-quality cars with the fewest defects of any competing manufacturer, while using fewer man-hours, less on-hand inventory, and half the floor space of its competitors. The Toyota Way is the first book for a general audience that explains the management principles and business philosophy behind Toyota's worldwide reputation for quality and reliability. Complete with profiles of organizations that have successfully adopted Toyota's principles, this book shows managers in every industry how to improve business processes by: Eliminating wasted time and resources Building quality into workplace systems Finding low-cost but reliable alternatives to expensive new technology Producing in small quantities Turning every employee into a qualitycontrol inspector




The Toyota Way - Achieving Operational Excellence through Principles and Practices


Book Description

In the corridors of corporate history, the Toyota Way is more than just a chapter; it's a testament to the art and science of exceptional management. It's a philosophy rooted in the pursuit of perfection, an unyielding commitment to efficiency, quality, and innovation. But it's not merely a set of principles etched in stone; it's a living, breathing philosophy that has adapted to changing times while holding steadfast to its core values. As we embark on this journey, prepare to uncover the secrets behind Toyota's unmatched success, the principles that have catapulted it to the zenith of operational excellence. From the relentless pursuit of continuous improvement to a profound respect for people, from a visionary long-term outlook to the relentless quest for value stream perfection, these principles are not just the building blocks of a successful automotive company. They are the cornerstones of a management philosophy that has reverberated far beyond Toyota's factories, influencing industries as diverse as healthcare, aerospace, and manufacturing. We will trace the genesis of the Toyota Way back to its roots, unveiling the cultural and historical contexts that shaped it. We will explore the profound influence of visionaries like Sakichi Toyoda and Kiichiro Toyoda, who sowed the seeds of this philosophy. We will delve into the principles of Jidoka and Poka-Yoke, introduced by Sakichi Toyoda, which laid the foundation for the Toyota Production System (TPS) – a linchpin of the Toyota Way. But this journey is not merely about the past; it's about the present and the future. We will examine how the Toyota Way continues to evolve and shape contemporary business practices, how it has transcended borders, how it resonates with the ever-essential values of employee engagement, customer-centricity, and quality. As we traverse the chapters of this book, be prepared for revelations that will inspire your approach to management, challenge your notions of excellence, and leave you with profound insights into what it takes to excel in the complex and dynamic world of business. The Toyota Way is not just a philosophy; it's a blueprint for excellence, a roadmap to enduring success. So, let's embark on this odyssey, guided by the principles that have made Toyota an icon of operational brilliance. Welcome to "The Toyota Way." Chapter One Introduction to the Toyota Way Chapter Two The Core Principles of the Toyota Way Chapter Three Continuous Improvement The Kaizen Philosophy Chapter Four Cultivating Respect for People Chapter Five Embracing Long-Term Thinking Chapter Six Streamlining Processes through Value Stream Mapping Chapter Seven Standardization and Simplification for Quality Chapter Eight Excellence in Inventory Management Just-in-Time Production Chapter Nine Building Quality into the Process The Built-in Quality Approach Chapter Ten Fostering Continuous Learning and Development Chapter Eleven Impact and Global Adoption Chapter Twelve Conclusion: The Enduring Legacy of the Toyota Way




Lean Lexicon


Book Description

With 14 new definitions touching on management, healthcare, startups, manufacturing, and service, the 5th edition of the Lean Lexicon, is the most comprehensive edition yet of the handy and practical glossary for lean thinkers. The latest Lexicon, updated in 2014, contains 60+ graphics and 207 terms from A3 Report to Yokoten. The Lexicon covers such key lean terms as andon, jidoka, kaizen, lean consumption, lean logistics, pull, plan-for- every-part, standardized work, takt time, value-stream mapping, and many more. The new terms are: • Basic Stability • Coaching • Gemba Walk • Huddle • Kamishibai Board • Kata • Leader Standard Work • Lean Management • Lean Management Accounting • Lean Startup • Problem Solving • Service Level Agreement • Training Within Industry (TWI) • Value-stream Improvement Unlike most other business glossaries in print or online, the Lexicon, introduced in January 2003, is focused exclusively on lean thinking and practice. Like the past four, the fifth edition of the Lean Lexicon incorporates terms and improvement ideas from our customers. We continue to welcome suggestions from the growing lean community in its traditional industries and beyond.




The Toyota Way - Management Principles and Fieldbook (EBOOK BUNDLE)


Book Description

Transform your company the Toyota way! Two essential guides streamlined into a SINGLE EBOOK PACKAGE Toyota. The name says it all: Innovation. Efficiency. Quality. Excellence. The Toyota Way—Management Principles and Fieldbook explains how the legendary automaker consistently achieves the highest levels of manufacturing and business success—and how you can achieve similar results with your own organization, regardless of your industry. Discover Toyota’s methods then learn how to put them to practical use with these groundbreaking books: The Toyota Way—INTERNATIONAL BESTSELLER! The Toyota Way reveals the management principles behind Toyota's worldwide reputation for quality and reliability. Dr. Jeffrey Liker, the global expert on Toyota's Lean methods, explains how you can implement the company’s principles to: Double or triple the speed of any business process Build quality into workplace systems Eliminate the huge costs of hidden waste Turn every employee into a quality-control inspector Dramatically improve your products and services The Toyota Way Fieldbook Written as a companion volume to The Toyota Way, this hands-on guide takes the lessons of Toyota to the next level. Liker teams up with Toyota veteran David Meier to provide the diagnostic tools, worksheets, and exercises you need to craft the most effective approach for your organization. Learn how to: Develop leaders that “live” your system Transform your company into a true lean learning organization Create a culture of continuous improvement and innovation Meet all the needs of your customers Position your company for long-term success