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Ninbennoaru Jidoka

Mind of a human to troubleshoot
      and correct failures

      Anand Subramaniam
“Everyone is a genius at least once a year; a
   real genius has his original ideas closer
                  together.”

                               - Georg Lichtenberg




                                                 2
Toyota Production System (TPS)

                             TPS
Single Piece
   Flow                                                Poka Yoke




                                              Jidoka
                              People
               JIT
    Pull                     Involve-
                               ment                     Andons

 Takt Time



                            Heijunka
               Sequencing               Leveling


                                                                   3
Jidoka
Automation with a human touch = Autonomation




 Origin of Jidoka - Type G
 Toyoda Automatic Loom

                                               4
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
Why use Jidoka ?

 Lower costs

 Increase quality

 Reduce lead time

 Improve customer service
                              6
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
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
Jidoka Process

 Poka Yoke Devices


                                        Investigate the
                      Fix or correct
 Detect the                            root cause and
              Stop   the immediate
abnormality                            install counter-
                        condition         measures




                                                      9
“Try to learn something about everything
     and everything about something.”

                         - Thomas Henry Huxley




                                            10
Good Luck
http://www.linkedin.com/in/anandsubramaniam




                                              11

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Ninbennoaru Jidoka

  • 1. Ninbennoaru Jidoka Mind of a human to troubleshoot and correct failures Anand Subramaniam
  • 2. “Everyone is a genius at least once a year; a real genius has his original ideas closer together.” - Georg Lichtenberg 2
  • 3. Toyota Production System (TPS) TPS Single Piece Flow Poka Yoke Jidoka People JIT Pull Involve- ment Andons Takt Time Heijunka Sequencing Leveling 3
  • 4. Jidoka Automation with a human touch = Autonomation Origin of Jidoka - Type G Toyoda Automatic Loom 4
  • 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. Why use Jidoka ?  Lower costs  Increase quality  Reduce lead time  Improve customer service 6
  • 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. 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. Jidoka Process Poka Yoke Devices Investigate the Fix or correct Detect the root cause and Stop the immediate abnormality install counter- condition measures 9
  • 10. “Try to learn something about everything and everything about something.” - Thomas Henry Huxley 10