Introduction to jidoka november 2016

1Marek.Piatkowski@Rogers.com
Jidoka
Introduction
Thinkingwin, Win, WIN
Introduction to Jidoka
Definitions
Marek Piatkowski – November 2016

Jidoka
Introduction
Introduction - Marek Piatkowski
 Professional Background
 Toyota Motor Manufacturing Canada (TMMC) - Cambridge, Ontario from
1987-1994
 TPS/Lean Transformation Consulting - since 1994
 Professional Affiliations
 TWI Network – John Shook, Founder
 Lean Enterprise Institute (LEI) – Jim Womack
 Lean Enterprise Academy (LEA) – Daniel Jones
 CCM/CAINTRA – Monterrey, Mexico
 SME, AME, ASQ, CME
 Lean Manufacturing Solutions - Toronto, Canada
http://twi-network.com

Jidoka
Introduction

Jidoka
Introduction
What is Jidoka?
 Jidoka is one of the two pillars of the Toyota Production System along with
Just-in-Time.
 There are two principles of Jidoka:
1. Separate man’s work from machine’s work
 Jidoka is sometimes called Autonomation gives equipment the ability to distinguish
good parts from bad autonomously, without being monitored by an operator
2. “Stop the Line and fix the problem”
 Stop and notify of abnormality - never let a defect pass to the next station
Stability
GOAL: Highest Quality, Lowest Cost, Shortest Lead Time
1. Stable Manufacturing Processes
2. 100% Quality Parts
Heijunka Standardized Work Kaizen
Just-in-Time Jidoka
Stop the line
and fix
the Problem
Separate man’s
work from
machine’s work
Continuous
Flow
Takt Time
Pull System
The Toyota House

Jidoka
Introduction
Jidoka - Autonomation
 Jidoka is a methodology to provide machines and operators with the ability to
detect when an abnormal condition has occurred and immediately stop the work.
 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.
 Jidoka is Autonomation, meaning automation with human intelligence:
 Jidoka frees the operator from watching the machine
 The need for operators not to continuously watch machines leads to large
productivity gains because one operator can handle several machines, often termed
multiprocess handling.
 Autonomation allows us to separate Operator’s work from Machine’s work
 Jidoka 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

Jidoka
Introduction
Jidoka Principles
 Jidoka also means – never letting a defect pass to the next station
 “Stop the Line – Fix the Problem”
 Jidoka highlights the causes of problems because work stops immediately when a
problem first occurs - this leads to improvements in the processes that build in
quality by eliminating the root causes of defects.
 Jidoka Steps:
 Detect the abnormality
 Turn on the Andon – or Stop
 Fix or correct the immediate condition
 Investigate the root cause and install a countermeasure

Jidoka
Introduction
Elements of Jidoka
 Andon – a visual control mechanism that displays the current state of work
 Green – status OK
 Yellow – call for help
 Red – Line stopped
 Fixed-Position Stop – a position on the assembly line where a zone process is
completed. It is at these positions that the line will stop should an abnormality be
not corrected on time – at the end of Takt Time.
 Line-Stop 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.
 Poka-Yoke - a low cost, highly reliable devices, used in the Jidoka system ,that will
stop processes in order to prevent the production of defective parts.

Jidoka
Introduction
How does Andon work?

Jidoka
Introduction
Fixed-Position Stop System
 In the Fixed-Position Stop System if an operator anywhere on the assembly line
notices an abnormality can stop the production flow by pulling a rope or by pushing
a stop button.
 Pulling the rope or pushing a stop button lights up a “number” or a “light” on a
large Andon signboard to call the Supervisor's attention to the problem.
 This action does NOT STOP the Production Line – it just issues a warning
 The Operator continuous working – finishing the rest of his Standard Work
 The Supervisor rushes to the station indicated and helps to correct the problem.
 When a problem has been resolved, the Supervisor pulls the rope again to prevent
the Line from stopping
 The Line STOPS ONLY when the problem is not resolved and the product (a car) has
reached the Fixed-Stop position

Jidoka
Introduction
Jidoka

Jidoka
Introduction
Poka-Yoke
 Poka-Yoke is a Japanese word translated as “foolproof mechanism”
 Poka-Yoke helps operators work easily and at the same time it eliminates troubles
associated with defects, safety, mistakes in operation, and so on without requiring
undue attention
 Even if the Operator makes a mistake, Poka-Yoke will prevent defects:
 will not start the machine or
 it will stop the machine.
 While Poka-Yoke or foolproof mechanism can eliminate defects, further
consideration must be given to the process capability of machines where numerous
factors can effect quality

Jidoka
Introduction
Two Types of Poka-Yoke
1. Warning - Indicates an error
situation requiring
intervention
2. Control – Stops production,
prevents mistakes

Jidoka
Introduction
Jidoka
There are four steps in developing Jidoka:
1. Minimizing manual labour - Manual labour simply means that all work is being done by
hand. This makes sense only when the labour costs are cheap and/or the manual work
can be done very quickly.
2. Introduction of mechanization - Mechanization means leaving part of the manual
operation to a machine. The work is shared between the Operator and the machine.
3. Automation - In this step all manual labour is taken over by the machine. The Operator
just loads the workpiece into the machine and presses a switch to start the machine.
The Operator can leave the machine alone, but there is no way to know whether the
machine is producing a good or a bad part.
4. Jidoka (Autonomation) - The operator simply presses the ON switch and leaves the
machine to do the processing. The machine will detect when a problem has occurred
and will automatically shut itself OFF. In addition to defect detection Jidoka sometimes
includes auto-input and auto-output. This completely eliminates the need for the
Operators participation

Jidoka
Introduction
Changing the World. One Kaizen at a time
This presentation is an intellectual property of W3 Group Canada Inc.
No parts of this document can be copied or reproduced
without written permission from:
Marek Piatkowski
W3 Group Canada Inc.
iPhone: 416-235-2631
Cell: 248-207-0416
Marek.Piatkowski@rogers.com
http://twi-network.com

Jidoka
Introduction
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Introduction to jidoka november 2016

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