History of jidoka, TPS, concept, role, principle and steps of jidoka. Tools of jidoka, Andon, Andon cord, Fixed-position stop, Poke-yoke with a pharmaceutical example

2. Toyota Production System
• Just In Time(JIT)
• JIDOKA
There are two pillars of
TPS

3. Stability and Standardization
Just in Time
•Continous flow
•Pull system
•flexible
workforce
Jidoka
andon
•Separate man
and machine
work
•Abnormality
identification
•Built in quality
Involvement of
people
Team building
Focuses on
Quality and
prevention
Goals:
Highest Quality
Lowest cost
Shortest lead time

4. JIDOKA
自 働 化
Self Movement -ization
AUTONOMATION

5. Introduction
• Jidoka is a technique to provide machines and operators with the ability to detect
when an abnormal condition has occurred and immediately stop the work.
• “Stop the Line and fix the problem”
• Jidoka is Autonomation, meaning automation with human intelligence.
• Jido- is applied to the machines with a built in device for making judgements,
• Whereas the regular ‘jido’ word in japanese means automation.
• Jidoka refers to the “automation with human touch”, refering to any machine that
moves under the automation, monitoring and supervision of an operator.

6. History of Jidoka
 The concept of Jidoka originated in
the early 1900s when Sakichi Toyoda,
founder of the Toyota Group, invented
a textile loom that stopped
automatically when any thread broke.
 Previously, if a thread broke the loom
would churn out mounds of defective
fabric, so each machine needed to be
watched by an operator.

7. Concept of Jidoka
Machine detects
a problem and
communicates it
A situation
deviates from
the normal flow
The line is
stopped
Responsible
person like
manager or
supervisor
removes the
problem
Improvements
incorporated
in the
standard flow.

8. Jidoka – The Tool of Built-in Quality
It allows the operation to have a build-
in quality at each step of a process, so
the operator does not have to “watch”
the machine or the operation..
It is based on:
• Don’t accept defects.
• Don’t make defects
• Don’t pass on defects

9. Role of Jidoka
Jidoka system in place, companies can ensure that
defects are not passed on to the customer.
Autonomation is an important component of Lean Manufacturing Strategy
for high-volume production, low-variety operations, particularly where
product life cycles are measured in years or decades.

10. Principles of Jidoka
Stop and respond to every abnormality
Separate machine work from human work
Enable machines to detect abnormalities and stop
autonomously
Assure quality of everything by confirming the
outcome of every process step.

11. Steps in Jidoka
Detect
abnormality
Stop
equipment or
line
Fix and
correct
immediate
condition
Investigate the
root cause and
install a
counter
measure.

12. Benefits of Jidoka
Autonomation Automation
People Production improves when
people are multi-process handler
Work is easier but people are
still “machine watching”
Machine Machine can detect errors and
stop autonomously
Machine run to end of cycle
until stop button is pressed
Quality Defects and machine crashes are
prevented by auto-stop
Machines crashes and mass
production of defects can occur
Response to
Problem
Errors cause machine to stop &
root cause can be found quicker
Errors are found later & root
cause correction takes longer
Increase
Quality
Lower
Costs
Improve
Customer
Service
Reduce
Lead
Time

13. Tools of Jidoka
Andon
Andon cord
Fixed-position stop
Poke-yoke

14. Andon is a typical tool to apply the Jidoka principle, which means the highlighting of
a problem, as it occurs, in order to immediately countermeasure the problem and
prevent re-occurrence.
Andon

15. Andon
• A visual control mechanism that displays the
current state of work.
• Andon is the Japanese word for “paper lantern”
• Refers to any visual display that shows status
information.
• Often combined with an audible signal such as an
alarm
In Japanese for 'sign' or 'signal'.
Machine is running as
desired
Machine has some
problems
Machine has
stopped

16. Andon- Example
 The green and red color indicates
machine status
 Green indicates the machine is functioning
normally.
 Red indicates that the machine has stopped.
 Fully programmable yellow represents
the maintenance status.
 Flashing yellow - maintenance personnel
required.
 Steady yellow - maintenance on site.

17. Andon Cord
A mechanism, usually a rope, that a worker may pull to signal the need for assistance
and which will stop the line if the problem is not fixed under takt time.
Fixed-Position Stop
 It is at these positions that the line will stop so that an abnormality can be corrected
on time

19. Poka-Yoke
 It is a Japanese word translated as “foolproof
mechanism”
 Poka-yoke refers to techniques using low-cost
devices or innovations that make it impossible to
make mistakes.
 Even if the Operator makes a mistake- Poka-Yoke
will prevent defects:
*Will not start the machine or
*It will stop the machine.
 Poka-yoke helps people and processes work right
the first time

21. Jidoka: Line Stop
 Authority to stop
 Fear of loss in productivity
 Initially painful
 Reduction in line stops

22. Line stop at
Line stop is a way
of life.
Operator detects a
problem .
Push a button.
Stop the production
line at the end of
that production
cycle.
Andon board is lit.
Alerts the team
leader or
supervisor.
Comes over to help
solve the problem.
Call in support.

23. Example: Pharmaceutical
Infusion (IV) Pump:
•Set up by a care provider.
The machine runs. The machine stops and an alarm
goes off when there is a problem.
• Solution runs out
• Line is occluded
• Air is detected
Tablet Punching Machine

24. Jidoka – Problem Solving
 Incorporation of autonomation
 Relatively simpler today
 Where we tend to fail?
 Train everyone-problem solving
 Update process documentation
 Communicate changes

25. Summary
“Autonomation”, means automation with a human touch.
1st used by Sakichi Toyoda, is one of two pillars of the Toyota Production System.
Important component of Lean Manufacturing Strategy for high-production, low-
variety operations.
Helps to detect a problem earlier, avoids the spread of bad practices.
Results in high-quality products.
Makes improvement in productivity.

26. Any questions?