The present work with this paper signifies the importance of safety and it’s enhancement in LFJ operations at Toyota weld shop. The benefits of applying the kaizen principles are manifold . Solutions here will emphasize on continual improvements in safety practices. Pokayoke makes a simple fool proof device like small jigs or even makeshift devices used to detect and avoid fault operation. Pokayoke here is set up in Kaizen context; where a problem comes up, analyzing finds out causes and Pokayoke will avoid it happening again with the little of modification in current system. This paper also proposes the method of impact awareness training to the team members through the preparation of process video manuals. The set of guidelines provided in video manuals will be useful to the member as it educates him in improving his mindset towards Safety and keeps him conscious of mistakes during any LFJ operations and impact.
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