Jidoka: Reliability, Quality, Poke Yoke

Jidoka:
Reliability, Quality, Poke Yoke
KIOT
Lean system engineering
Target group: 3rd year GED
Chapter six
By: Endashaw Yohannes
Kombolcha/Ethiopia
May , 2019
5/31/2019 1
Jidoka:
Reliability, Quality, Poke Yoke

5/31/2019 2
Jidoka Concept – Sakichi Toyoda
Jidoka has been defined as
“automation with a human mind”
 Humans make mistakes
• Since humans work in the system, you can never eliminate
mistakes
 Machines make defects
• Since machines are supervised by humans, use the humans to
find and fix the machines that make defects
 “… thus Zero defects is absolutely possible.”
– Shigeo Shingo

5/31/2019 3
Jidoka
Human
Error
Rates:
Dennis (2015)
p. 126

5/31/2019 4
Jidoka Concept
 Really, we are leveraging on Process Capability:
• Old World Mfg – produce as much and as fast as possible.
Replace defective products when someone complains.
• New World Mfg – NEVER pass on a defective product. Stop the
line and fix the process … and continually improve the process
 By continually strengthening Jidoka, we are improving our
process capability, and putting our firm in a better position for
the future.
• Focus on improving process capability (Poke Yoke) – by
investigating defect causes and fixing the machines that cause
them and by eliminating human mistakes
• Focus on containing defects (Zone Control)– by having people
find defects and containing them within the zone of control

5/31/2019 5
House of Lean
STABILITY
STANDARDIZATION
JUST IN TIME
CUSTOMER FOCUS
INVOLVEMENT
Standardized Work
5S
TPM
Kaizen Teams
Suggestions
Safety Activities
Hoshin Planning
Standardized Work, 5S, TPM Jidoka, Heijunka, Kanban
Standardized Work
Kanban, A3 Thinking
Visual Order (5S)
Hoshin Planning, Takt, Heijunka
Involvement, Lean Design, A3 Thinking
JIDOKA
 Poke Yoke
 Zone Control
 Visual Order (5S)
 Problem Solving
 Abnormality
Control
 Separate Human
& Machine Work
 Involvement
 Flow
 Heijunka
 Takt Time
 Pull System
 Kanban
 Visual Order (5S)
 Involvement

2 - 6SKB
Jidoka is…
A.
A method for reducing defects
B.
Equipment autonomation
to improve productivity

2 - 7SKB
Jidoka
A. Tools or Methods to Reduce Defects
 Detect defects when they occur
 Prevent defects from passing to next operation
 Identify root causes of defects
 Eliminate root causes
 Reduce or eliminate defects

2 - 8SKB
Jidoka Elements
 Visual Control
 5S
 Andon
 Abnormality
Response/Reaction
 Roles and responsibilities
 Line stop guidelines
 Sigma Kaizen (DMAIC)
 Basic QC Tools
 Advanced Statistical Tools
 Counter measures
 Mistake-proofing (Poke-Yoke)
 Manual Work
 Automatic machine work
 New Standard Operations and
training
 Skill matrix and performance
 Autonomation
 Separate person from
machine

2 - 9SKB
Jidoka Elements
Visual Control
 5S
 Andon
Parts
presentation
Tool
presentation
Pack line
Andon
Standard
work

2 - 10SKB
Abnormality Response Process
React to problem
Q C D S
Measure impact
Alert team
Train affected associates in new
standard operations
MAN
EFFECT
MACHINE
MATERIALMETHOD
Find root cause
Develop and test
improvement
Check 2B
Gauge 4
Update standard operations with
tested improvement

5/31/2019 11
Poke Yoke
Most Common Errors:
• Missing Process Steps
• Process Errors (does not meet standard)
• Mis-set Work Pieces (piece set backwards)
• Missing Parts
• Wrong Parts
• Faulty Machine Operation
• Adjustment Error (depth of cut stop set wrong by operator)
• Equipment Set Up Wrong
• Tools / Fixtures / Jigs Inadequately Prepared
A Good Poke Yoke either prevents these or makes an error obvious:
• Simple, with a long life
• Highly reliable
• Low cost
• Designed for workplace conditions

5/31/2019 12
Poke Yoke Examples
A Good Poke Yoke either
prevents errors or makes an
error obvious:
• Humans are not good at
simple, repetitive
motions (like sorting
clips)
• Machines can do the
same action repeat ably

2 - 13SKB
Jidoka
B. Equipment autonomation
Separate operator work from machine work
Before: Operator watches machine run
After: Operator loads and moves
 Auto shut-off
 “Hanedashi” auto unload
 Operator moves to next operation

2 - 14SKB
Jidoka Benefits
 Increases production quality
 Increases productivity
 Ensures on-time delivery
Quality ... Cost ... Delivery!

5/31/2019 15
Jidoka Implementation
Involvement is Everything: people love to solve problems.
 SMART Goals:
• Simple
• Measurable
• Achievable
• Reasonable (relevant)
• Trackable
 Motivation:
• Extrinsic Motivation – comes from physical rewards
• Monetary
• Gifts
• Intrinsic Motivation – comes from personal satisfaction
• Recognition by peers
• Personal growth (skills development) & self-actualization (self-accomplishment)
• Contribution to a broader / larger goal

The Value Stream
 Value Stream is “All the actions … currently
required to bring a product through the main
flows essential to every product”.
• Big picture, not individual processes
• Both value added and non value added
• Material, information, and people flows
• Across organizational boundaries

What is a Value Stream Map?
 The Current State Value Stream Map is a particular type of map
that documents the process flow in a Value stream, starting
with the customer, and focusing on every step, both value
added and non value added.
 The value stream map documents the people, material, and
information flows that make up the value stream.
 The Value Stream Map also documents data about the process
including process time, cycle time, change over time, work in
process.

Create a future state value stream map;
contact through

How to Value Stream Map; for an editable
or customized version contact through
Leanmanufacturingtools.org

Create a future state value stream map; contact through
leanmanufacturingtools.org for a customized or editable version

Jidoka: Reliability, Quality, Poke Yoke

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