MonozukuriIn daily lifeIn JapanGroup E
Group E 2
Monozukuri : Making things
What is Monozukuri
• Monozukuri is a Japanese word consisting of “mono” which
means“products,” and “zukuri” which means “process of making or
creation.”However, the word means more than simply making
something; it has overtones of excellence, skill, spirit, zest, and
pride in the ability to make things very well.
• So Monozukuri = Hito zukuri ( Hito = people )
Learning from Prof. Furuhashi on Monozukuri
Group E 3
Monozukuri : Making things
Information
Material
PeopleMachine
Material
Procurement
Manufacturing
Processing
Shipment
delivery
Products:Are they meeting
requirements?
Products:Are they meeting
requirements?
Resources:Are they
being used effectively?
Resources:Are they
being used effectively?
Processes:Are they running
smoothly?
Processes:Are they running
smoothly?
Basis of workplace:Is safety guaranteed
all the time?
Basis of workplace:Is safety guaranteed
all the time?Model By Prof Furuhashi
PeopleHow are we developing
people
PeopleHow are we developing
people
Fundamentals taught by Prof. Furuhashi on Toyota way
Group E 4
Monozukuri : Making things
Focus o
n b
asic
s
SM
ED
Jid
oka
Vis
ual co
ntr
ol
Space u
tiliz
atio
n
3R
regu
latio
ns
Kara
kuri k
aiz
ens
Ecolo
gy
Poka
yoke
Just
in t
ime
Continuous Improvement Through kaizen
Five S
Waste elimination
Grow, sustainable, make profit
Create Culture
Develop Own Production System
Serve Society
SmoothRunning ofproduction
Defect freeProduct
To customerSafety
Care forEnvironment
Human Resource
Development
Model based on learning of Toyota, Komatsu and Nissan Visits
Group E 5
Monozukuri : Making things
Focus o
n b
asic
s
SM
ED
Jid
oka
Vis
ual co
ntr
ol
Space u
tiliz
atio
n
3R
regu
latio
ns
Kara
kuri k
aiz
ens
Ecolo
gy
Poka
yoke
Just
in t
ime
Observation of daily life in Japan showing these concepts.
Group E 6
Monozukuri : Making things
CommentSymbolic Observation
• While visiting the fort we could observe that 5S has become
obvious part of their life.
Five S
Group E 7
Monozukuri : Making things
CommentSymbolic Observation
• One of the best example of fool proofing is the gates at the station.
• One more example is the provision mad for locking the cycles on
the stands
Pokayoke
Lock Visual indication
Group E 8
Monozukuri : Making things
CommentSymbolic Observation
• Maps indicating the stations on the root and direction of movement
are excellent example of visual control used in daily life
• One more good example is the visual display of food items
Visual Controls
Group E 9
Monozukuri : Making things
CommentSymbolic Observation
• Many places the vertical space is utilised for car parking. The
automation ( jidoka ) used is also visible in the picture
Space utilisation
Group E 10
Monozukuri : Making things
CommentSymbolic Observation
• The place is marked for every thing. The name is also displayed on
the location. Car parking visible from our hotel is an example
shown here
3R regulation
Group E 11
Monozukuri : Making things
Symbolic Observation
• At crossing people follow the signals and wait for green signal to
cross. The signal is also audio visual for making then alert
• Special walkways are created for blind people
• In one place where it was essential to take support two separate
holding bars were provided for adults and children
safety
Group E 12
Monozukuri : Making things
Symbolic Observation
• Waste is colleted in a systematic manner separating recyclable
and others . Messages like “Save earth’ are displayed on bins
• All toilets have automation for water flow to conserve water.
Environment
Group E 13
Monozukuri : Making things
Symbolic Observation
• Just in time principle is followed unknowingly in daily life. The
people standing in the queue do not cross yellow line unless the
desk is free.
• The train arrives on time and stands exactly at the given location
Just In Time
Group E 14
Monozukuri : Making things
Symbolic Observation
• It is said jokingly that even the flowers blossom just in time before
valentine’s day
Just In Time
Group E 15
Monozukuri : Making things
Symbolic Observation
• In many shops innovative ideas are found which are useful for
daily life
• Karakuri kaizen it self is famous and the photo shown is a karakuri
doll using principle of hanging weight.
• Automated commode is another example
Karakuri Kaizens
Group E 16
Monozukuri : Making things
Symbolic Observation
• In shinkansen, the seat direction can be changed within few
seconds to change the direction to other side when train changes
the direction
SMED
Group E 17
Monozukuri : Making things
Symbolic Observation
• We could observe young generation visiting Nissan factory and
Toyota museum which will definitely create impact of the industrial
developments Japan has and help in transferring the cultured
developed to next generation.
Create Culture
End of Presentation