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Jidoka Sample


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Jidoka Sample

  1. 1. Jidoka Superfactory Manufacturing Excellence Series Lean Overview 5S & Visual Factory Cellular Manufacturing Jidoka Kaizen Poka Yoke & Mistake Proofing Quick Changeover & SMED Production Preparation Process (3P) Pull Manufacturing & Just In Time Standard Work Theory of Constraints Total Productive Maintenance Training Within Industry (TWI) Value Streams
  2. 2. Contents © 2007 Superfactory™. All Rights Reserved. <ul><li>Introduction </li></ul><ul><li>Background and History </li></ul><ul><li>Components and Implementation </li></ul><ul><ul><li>Why Jidoka? </li></ul></ul><ul><ul><li>What does Jidoka do? </li></ul></ul><ul><ul><li>History </li></ul></ul><ul><ul><li>Prevention Techniques </li></ul></ul><ul><ul><li>Jidoka Steps </li></ul></ul><ul><li>Knowledge Check </li></ul>
  3. 3. Introduction © 2007 Superfactory™. All Rights Reserved. <ul><li>Jidoka is providing machines and operators the ability to detect when an abnormal condition has occurred and immediately stop work. This enables operations to build-in quality at each process and to separate men and machines for more efficient work. </li></ul><ul><li>Jidoka is one of the two pillars of the Toyota Production System along with just-in-time. </li></ul><ul><li>Jidoka is sometimes called autonomation, meaning “automation with human intelligence”. </li></ul>
  4. 4. Components and Implementation © 2007 Superfactory™. All Rights Reserved. <ul><li>What is Jidoka? </li></ul><ul><li>Why Jidoka? </li></ul><ul><li>What does Jidoka do? </li></ul><ul><li>History </li></ul><ul><li>Prevention Techniques </li></ul><ul><li>Jidoka Steps </li></ul><ul><ul><li>Detect </li></ul></ul><ul><ul><li>Stop </li></ul></ul><ul><ul><li>Fix </li></ul></ul><ul><ul><li>Investigate </li></ul></ul>
  5. 5. What is Jidoka? © 2007 Superfactory™. All Rights Reserved. <ul><li>Quality must be built in during the manufacturing process! </li></ul><ul><ul><li>If a defective part or equipment malfunction is discovered, the machine automatically stops, and operators stop work and correct the problem. </li></ul></ul><ul><ul><li>For the Just-in-Time system to function, all of the parts that are made and supplied must meet predetermined quality standards. This is achieved through jidoka. </li></ul></ul>
  6. 6. Jidoka Steps © 2007 Superfactory™. All Rights Reserved. <ul><li>The four steps in Jidoka are: </li></ul><ul><ul><li>Detect the abnormality. </li></ul></ul><ul><ul><li>Stop. </li></ul></ul><ul><ul><li>Fix or correct the immediate condition. </li></ul></ul><ul><ul><li>Investigate the root cause and install a countermeasure. </li></ul></ul>
  7. 7. Detect and Stop © 2007 Superfactory™. All Rights Reserved. <ul><li>The first two steps can be mechanized or automated. </li></ul><ul><ul><li>Poka-yoke devices are one method to allow a process to detect a problem and stop. But if you take a broader view, every one of the mechanisms of the Toyota production system is really designed to do these two things. </li></ul></ul>
  8. 8. Detect and Stop © 2007 Superfactory™. All Rights Reserved. <ul><li>Time itself can be a powerful detection mechanism if work cycles are paced to the takt time. </li></ul><ul><ul><li>What should be complete 25% into the takt time? How about 50%? Is the work progressing the way you expect it to? There is a huge opportunity to detect a problem when there is enough time to respond--instead of discovering at the end of the day (or week) that things are way behind. If the team member is given the means to immediately signal that she has encountered a problem (via andon, for example), then the response can be immediate. </li></ul></ul>