Jidoka is a way of spotting problems and taking prompt action to correct faults at any stage in the production process. Machinery will automatically detect an issue and safely stop so that an inspection and any necessary adjustments can be made. Information is shared with others on the “andon” display board and operators can continue working on other machines. In this way the system helps prevent problems from happening again while maintaining quality and high productivity.

Just-in-time means making only what is needed, when it is needed, at every stage of production. That means there is no waste, consistent quality and an even production flow. It requires the production line to be stocked with all the right parts, in the right sequence at the moment production begins. As parts are used up, new stock is delivered at the right time, in the right quantity so there is no interruption or slow-down in the production process. The kanban system is central to the just-in-time process, providing an automatic, real-time method to replenish parts at the line side and keep minimal stock.