nchi Genbutsu (現地現物: Toyota Production System

TQM lay particular stress on the following:-
1) Meeting the needs and expectations of customers

2) Covering all parts of the organization
3) Including every person in the organization
4) Examining all costs which are related to quality, especially failure cost
5) Getting things right first time i.e. designing in quality in quality rather than
inspecting it in
6) Developing the system and procedures which support quality and improvement
7) Developing a continuous process of improvement.
Some Japanese terms:-
1.Genchi Genbutsu (現地現物?) means "go and see" and it is a key principle of
the Toyota Production System. It suggests that in order to truly understand a situation
one needs to go to gemba (現場) or, the 'real place' - where work is done.
Taiichi Ohno, creator of the Toyota Production System is credited, perhaps

apocryphally, with taking new graduates to the shopfloor and drawing a chalk circle on
the floor. The graduate would be told to stand in the circle, observe and note what he
saw. When Ohno returned he would check; if the graduate had not seen enough he
would be asked to keep observing. Ohno was trying to imprint upon his future engineers
that the only way to truly understand what happens on the shop floor was to go there. It
was where value was added and waste could be observed.
Genchi Genbutsu is therefore a key approach in problem solving. If the problem exists
on the shop floor then it needs to be understood and solved at the shop floor.
2.Jidoka is one of the two pillars of the Toyota Production System along with just-in-
time. Jidoka highlights the causes of problems because work stops immediately when a
problem first occurs. This leads to improvements in the processes that build in quality by
eliminating the root causes of defects.
The term jidoka used in the TPS (Toyota Production System) can be defined as
"automation with a human touch." The word jidoka traces its roots to the invention of the
automatic loom by Sakichi Toyoda, Founder of the Toyota Group. The automatic loom
is a machine that spins thread for cloth and weaves textiles automatically. 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.
Since the loom stopped when a problem arose, no defective products were produced.
This meant that a single operator could be put in charge of numerous looms, resulting in
a tremendous improvement in productivity.
2. Heijunka is a Japanese term for a level loading of demand and is a fundamental
component of a pull system. It s also known as production levelling or production
smoothing and its aim is to produce items at a constant rate so that they flow
through the production process with minimum lead time and no waiting.
3. a)5S- Seiri or Sort b) Seiton or Straighten / Set in order c) Seiso or Sweep /

shine d) Seiketsu or Standardize e) Shitsuke or Sustain
4. The original Japanese was "boka yoke." That actually means "idiot proof." It was
changed to poka yoke, meaning mistake proof, because it seemed less
demeaning. It is imperative that we remember who designs and approves
processes. Management is responsible for the process that can be done wrong.
They need to own up to that, and take the time to correct it.
Poka - Yoke is, is a defect prevention (early defect detection) technique

used in Design and Manufacturing of products. It teaches that - "If you
don't want to do a mistake, plan for not doing it by mistake proofing".
5C and CANDO
There has been reluctance for some companies in the past to take up “Japanese”
initiatives for business improvement, so some consultancies and other bodies have
come up with non-Japanese equivalents; two of which are listed below as alternatives
for 5S.
5S is also known in some quarters as 5C, with the “S” words replaced by
 Clearing,
 Configure,
 Clean and Check,
 Conformity and finally
 Custom and practice.
CANDO is;
 Cleanup,
 Arrange,
 Neatness,
 Discipline, and
 Ongoing Improvement.

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nchi Genbutsu (現地現物: Toyota Production System

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TQM lay particular stress on the following:-

1) Meeting the needs and expectations of customers

Some Japanese terms:-

Taiichi Ohno, creator of the Toyota Production System is credited, perhaps

3. a)5S- Seiri or Sort b) Seiton or Straighten / Set in order c) Seiso or Sweep /

Poka - Yoke is, is a defect prevention (early defect detection) technique

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