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Ninbennoaru Jidoka


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Ninbennoaru Jidoka

  1. 1. Ninbennoaru JidokaMind of a human to troubleshoot and correct failures Anand Subramaniam
  2. 2. “Everyone is a genius at least once a year; a real genius has his original ideas closer together.” - Georg Lichtenberg 2
  3. 3. Toyota Production System (TPS) TPSSingle Piece Flow Poka Yoke Jidoka People JIT Pull Involve- ment Andons Takt Time Heijunka Sequencing Leveling 3
  4. 4. JidokaAutomation with a human touch = Autonomation Origin of Jidoka - Type G Toyoda Automatic Loom 4
  5. 5. What is Jidoka ? The Japanese word for “autonomation” Toyota Motor defines the word as, “investing machines with human intelligence.” Can be used with machines or people One of the two main pillars of TPS (Toyota Production Systems) Machines are designed to stop automatically when a problem is detected or any operator on the line, has the power to stop production 5
  6. 6. Why use Jidoka ? Lower costs Increase quality Reduce lead time Improve customer service 6
  7. 7. Ninbennoaru Jidoka Alerts the worker, when a defective item is produced or a machine malfunction has occurred  This allows the problem to be dealt with immediately, preventing the production and passing of defects  Problems and the defects they cause, can be more quickly localised, isolated, and corrected . 7
  8. 8. Prevention Techniques Poka Yoke  Visual control of quality  Prevents defects from happening Andons  Light to signal production line status / attention • Red: line stopped • Yellow: call for help • Green: all normal Pin-Pan-Pon 8
  9. 9. Jidoka Process Poka Yoke Devices Investigate the Fix or correct Detect the root cause and Stop the immediateabnormality install counter- condition measures 9
  10. 10. “Try to learn something about everything and everything about something.” - Thomas Henry Huxley 10
  11. 11. Good Luck 11