Category Archives: Toyota

Any posts related to companies from the Toyota Group, including Toyota Motor, Denso, etc., and its people.

Examples of Jidoka

In my last two posts I talked a lot about what jidoka is, and the underlying philosophy. Many articles do so. But there are almost no actual examples out there of jidoka. But without examples it is difficult to really understand a concept. A great historic example of this is the Toyoda Model G automatic loom from 1925. This is well known, but here I would like to show you how it connects to jidoka. I will also give you a more modern example of a product that you may even own.

Continue reading Examples of Jidoka

The Philosophy and Practicality of Jidoka

In my last post I explained what jidoka is (at least in my view). The key part is to stop the line for any irregularity, and resolve the problem.  Also try to make sure this irregularity does not happen again. However, this definition is far from universally accepted, and there are many different opinions. Here I will try to show the philosophical idea behind Jidoka as one of the two pillars of the Toyota Production System (the other is JIT). Continue reading The Philosophy and Practicality of Jidoka

What Exactly Is Jidoka?

Jidoka is a term commonly used in lean manufacturing, and widely considered one of the pillars of the Toyota Production System, the other being Just in Time (JIT). However, while the word jidoka is often used to impress others, the ideas behind it are much less frequently found outside of Toyota. Maybe this is because so many people interpret jidoka differently. In this first post of a three post series on jidoka, we look at what jidoka actually is. Continue reading What Exactly Is Jidoka?

Toyota Standard Work – Part 3: Standard Work Layout

This post is the third in this series on how Toyota plans standard work. The first one was the production capacity sheet to define what capacity you have available. The second one was a standard work combination table to define when the operator is doing what. Finally, the third of the “famous three slips”, presented in this post, is a standard work layout sheet to help the layout and arrangement of the machines. Continue reading Toyota Standard Work – Part 3: Standard Work Layout

Toyota Standard Work – Part 2: Standard Work Combination Table

Toyota has a nifty way to plan the work of an operator using their standard work charts. In my last post I explained the production capacity sheet to define what capacity you have available. In this post we will talk about the second of the “famous three slips”,  the standard work combination table to define when the operator is doing what. A subsequent post will show a standard work layout sheet. Continue reading Toyota Standard Work – Part 2: Standard Work Combination Table

Toyota Standard Work – Part 1: Production Capacity

Toyota is excellent with their standard work. They use a series of worksheets to simplify the creation of these standards.  These are sometimes also know as the “famous 3 slips”. The first one is a production capacity sheet to define what capacity you have available. The second one is a standard work combination table to define when the operator is doing what. The third one is a standard work layout sheet to help with the layout and arrangement of the machines. While there are many different ways of doing this, I like the Toyota approach. Since this is a larger topic, I’ve broken it into multiple blog posts. Lets start with the Production Capacity sheet. Continue reading Toyota Standard Work – Part 1: Production Capacity

The Grand Tour of Japanese Automotive – Overview and Toyota

Grand Tour of Japanese Automotive MapDuring Winter 2017–2018, I spent five months in Japan. As part of this visit, I was able to visit factories of all seven Japanese car makers as part of my Grand Tour of Japanese Automotive Plants.

This was extremely insightful, and I learned a lot about the differences between the Japanese car makers.  Let me give you an overview and some details on Toyota plants before firing off a series of blog posts on the different Japanese automotive companies. Continue reading The Grand Tour of Japanese Automotive – Overview and Toyota

Continued Evolution of the Toyota Assembly Line

Toyota LogoToyota is one of the the most visionary car makers with respect to its manufacturing. They continuously and radically evolve and update their production system. Recently I learned about their new “flexible assembly line.” Now, you’ve probably heard about Toyota’s flexible assembly lines producing multiple products on the same line. That is old hat; they’ve done that for thirty years. Their new flexible assembly line involves a completely different aspect of flexibility, with which Toyota surprised me (again). Let me show you … Continue reading Continued Evolution of the Toyota Assembly Line