Computational Method, Genchi-Genba Concept, and Monozukuri
Computational methods not only save time and energy of human calculation, but also
provide details in virtual reality conditions under well controlled initial and boundary
conditions that may be difficult to achieve by experiments. However, all computer
models, either simple or complex, include assumptions. Before computer models are
applied to simulate the actual problems, therefore, they all need to be validated against
full scale experiments, scale model tests or plant site observation. Validation by more
than one of these three helps researchers and engineers to enhance their understanding of
the problem.
Special emphasis should be given to the importance of plant site observation, known
as “Genchi-Genba”, an age-old Japanese philosophy in monozukuri. “Genchi” means,
roughly, exact location; “Genba” refers to function. The philosophy underlines the
importance of interacting with things and problems directly, and in a specific context.
It’s a way to contextualize problem-solving in a very concrete way. Progress in high
speed computers made it possible us to simulate and calculate many industry problems
and phenomena in a relatively short time. It should be noted, however, that the Genchi-
Genga concept is the basics for all industry problem solving processes and should be
practiced before we conduct computation, analysis or experiments. Toyoda Saikichi
reminds us of the value of on-site observation; he once described for an interviewer how
he came up with the Toyota auto-activated loom. We should note the absence of
advanced technology and computation in his description:
In my village, every family farmed and each house had a hand-weaving machine.
Influenced by my environment, I gradually began thinking about this hand-weaving
machine. Sometimes I would spend all day watching the grandmother next door
weaving.