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© Operational Excellence Consulting. All rights reserved.
Detect :: Fix :: Prevent
Jidoka
© Operational Excellence Consulting. All rights reserved. 2
Learning Objectives
1. Understand the key concept and principles of Jidoka
2. Familiarize with the tools of Jidoka
3. Define the four steps of a Jidoka process
4. Acquire knowledge on developing a Jidoka system
© Operational Excellence Consulting. All rights reserved. 3
1
2
3
4
Tools of Jidoka
Introduction to Jidoka
Four Steps of Jidoka
Developing a Jidoka System
Outline
NOTE: This is a PARTIAL PREVIEW. To
download the complete presentation, please visit:
http://www.oeconsulting.com.sg
© Operational Excellence Consulting. All rights reserved. 4
Introduction to Jidoka
Jidoka is a technique to provide machines and
operators with the ability to detect when an
abnormal condition has occurred and
immediately stop the work.
Jidoka is also known as autonomation, meaning
“automation with human intelligence” or “intelligent
machines.”
© Operational Excellence Consulting. All rights reserved. 5
Jidoka is one of the two pillars of the Toyota
Production System along with Just-In-Time
Stability
Heijunka Standardized Work Kaizen
Just-In-Time
• Continuous flow
• Takt time
• Pull system
• Flexible workforce
Jidoka
• Separate man &
machine work
• Abnormality
Identification
• Poka yoke
Goals:
highest quality,
lowest cost, shortest lead times
Involvement
Focuses on
Quality and
Prevention
© Operational Excellence Consulting. All rights reserved. 6
Jidoka – The Tool of Built-in Quality
 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 is based on:
 Don’t accept defects
 Don’t make defects
 Don’t pass on defects
© Operational Excellence Consulting. All rights reserved. 7
Principles of Jidoka
 Separate man’s work from machine’s work
 Man’s work and machine’s work are separated for better
efficiency
 “Stop the line and fix the problem”
 Stop and notify of an abnormality - never let a defect pass to
the next station
 Build-in quality at each process
 Attacks waste at the source
 Develop a mindset of doing it right the first time
 Prevention
 Analyze the root causes, implement countermeasures and
improve continuously
© Operational Excellence Consulting. All rights reserved.
“Stopping the machine
when there is trouble
forces awareness on
everyone. When the
problem is clearly
understood,
improvement is
possible.”
Taiichi Ohno
© Operational Excellence Consulting. All rights reserved. 9
Concept of Jidoka
Source: Toyota
A machine detects a
problem and
communicates it
Improvements
incorporated into the
standard workflow
Manager/supervisor
removes cause of the
problem
The line is
stopped
A situation deviates
from the normal
workflow
Daily improvements
1
2
4 5
3
© Operational Excellence Consulting. All rights reserved. 10
Benefits of Practicing Jidoka
 Defects are not passed on to the
next process (the “Customer”)
 Equipment breakdown is
prevented because problems
and their causes become
immediately apparent
 Machine work is separated from
Human work so that team
members can operate multiple
machines (savings in
manpower)
© Operational Excellence Consulting. All rights reserved. 11
Tools of Jidoka
 Andon
 Andon cord
 Fixed-position stop
 Poke-yoke
 Sensors
© Operational Excellence Consulting. All rights reserved. 12
What is Andon?
 Andon is the Japanese word for
“paper lantern”
 Refers to any visual display
that shows status information
 Often combined with an audible
signal such as an alarm
 Andons are erected to signal
when the line is stopped for
defects, or difficulties on the
line, and as signals for
replenishments for parts
#1 #2 #3 #4
ANDON BOARD
Green = Normal Operation
Yellow = Call for Help
Red = Line is Down
© Operational Excellence Consulting. All rights reserved. 13
Andon Cord
 Andon 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
© Operational Excellence Consulting. All rights reserved. 14
Fixed-Position Stop
 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.
Source: Adapted from Lean Enterprise Institute
Fixed-Position
Stop
© Operational Excellence Consulting. All rights reserved. 15
Activity: Andon
 In your respective groups, discuss when and
where andons can potentially be erected in
your work areas to signal the following
conditions:
1. When the line is stopped for defects
2. When difficulties are encountered on the line
3. When replenishments for parts are required
 List your ideas on the flip chart.
 Present your ideas to the class.
Time: 10 mins
© Operational Excellence Consulting. All rights reserved. 16
What is Poka-Yoke?
 Poka-yoke is a Japanese
term which means “mistake-
proofing” or “error-proofing”
 Poka-yoke refers to
techniques using low-cost
devices or innovations that
make it impossible to make
mistakes
 Poka-yoke helps people and
processes work right the first
time
© Operational Excellence Consulting. All rights reserved. 17
Conditions for Poka-Yoke
 The goal is zero defects
 Design must be based on
actual worksite conditions
 Devices must be
economical
 Devices must be simple
with long life and low
maintenance
© Operational Excellence Consulting. All rights reserved. 18
Three Rules of Poka-Yoke
1. Don’t wait for the perfect poka-yoke. Do it now!
2. If your poka-yoke idea has better than 50% chance to
succeed… Do it!
3. Do it now... improve later!
© Operational Excellence Consulting. All rights reserved. 19
1
2
3
4
Stop the equipment or line
Detect the abnormality
Fix or correct the immediate condition
Investigate the root cause and install
a countermeasure
Four Steps of Jidoka
© Operational Excellence Consulting. All rights reserved.
“Every defect is a
treasure, if the
company can uncover
its cause and work to
prevent it across the
corporation.”
Kiichiro Toyoda,
Founder of Toyota
© Operational Excellence Consulting. All rights reserved. 21
Activity: Four Steps of Jidoka
 In your respective groups, discuss plans for the
adoption or adaptation of the four steps of
Jidoka in your business/office processes. You
may focus your discussion on a pilot line.
 List your ideas on the flip chart.
 Present your ideas to the class.
Time: 10 mins
© Operational Excellence Consulting. All rights reserved. 22
Minimize
Manual
Labor
Mechanize
Automate
Jidoka
Current
State
Future
State
Developing a Jidoka System
© Operational Excellence Consulting. All rights reserved.
About
Operational Excellence
Consulting
© Operational Excellence Consulting. All rights reserved. 24
About Operational Excellence
Consulting
 Operational Excellence Consulting is a management
training and consulting firm that assists organizations in
improving business performance and effectiveness.
 The firm’s mission is to create business value for
organizations through innovative operational excellence
management training and consulting solutions.
 OEC takes a unique “beyond the tools” approach to enable
clients develop internal capabilities and cultural
transformation to achieve sustainable world-class excellence
and competitive advantage. For more information, please visit
www.oeconsulting.com.sg
© Operational Excellence Consulting. All rights reserved.
END OF PREVIEW
To download this presentation,
please visit:
www.oeconsulting.com.sg

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Jidoka by Operational Excellence Consulting

  • 1. © Operational Excellence Consulting. All rights reserved. Detect :: Fix :: Prevent Jidoka
  • 2. © Operational Excellence Consulting. All rights reserved. 2 Learning Objectives 1. Understand the key concept and principles of Jidoka 2. Familiarize with the tools of Jidoka 3. Define the four steps of a Jidoka process 4. Acquire knowledge on developing a Jidoka system
  • 3. © Operational Excellence Consulting. All rights reserved. 3 1 2 3 4 Tools of Jidoka Introduction to Jidoka Four Steps of Jidoka Developing a Jidoka System Outline NOTE: This is a PARTIAL PREVIEW. To download the complete presentation, please visit: http://www.oeconsulting.com.sg
  • 4. © Operational Excellence Consulting. All rights reserved. 4 Introduction to Jidoka Jidoka is a technique to provide machines and operators with the ability to detect when an abnormal condition has occurred and immediately stop the work. Jidoka is also known as autonomation, meaning “automation with human intelligence” or “intelligent machines.”
  • 5. © Operational Excellence Consulting. All rights reserved. 5 Jidoka is one of the two pillars of the Toyota Production System along with Just-In-Time Stability Heijunka Standardized Work Kaizen Just-In-Time • Continuous flow • Takt time • Pull system • Flexible workforce Jidoka • Separate man & machine work • Abnormality Identification • Poka yoke Goals: highest quality, lowest cost, shortest lead times Involvement Focuses on Quality and Prevention
  • 6. © Operational Excellence Consulting. All rights reserved. 6 Jidoka – The Tool of Built-in Quality  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 is based on:  Don’t accept defects  Don’t make defects  Don’t pass on defects
  • 7. © Operational Excellence Consulting. All rights reserved. 7 Principles of Jidoka  Separate man’s work from machine’s work  Man’s work and machine’s work are separated for better efficiency  “Stop the line and fix the problem”  Stop and notify of an abnormality - never let a defect pass to the next station  Build-in quality at each process  Attacks waste at the source  Develop a mindset of doing it right the first time  Prevention  Analyze the root causes, implement countermeasures and improve continuously
  • 8. © Operational Excellence Consulting. All rights reserved. “Stopping the machine when there is trouble forces awareness on everyone. When the problem is clearly understood, improvement is possible.” Taiichi Ohno
  • 9. © Operational Excellence Consulting. All rights reserved. 9 Concept of Jidoka Source: Toyota A machine detects a problem and communicates it Improvements incorporated into the standard workflow Manager/supervisor removes cause of the problem The line is stopped A situation deviates from the normal workflow Daily improvements 1 2 4 5 3
  • 10. © Operational Excellence Consulting. All rights reserved. 10 Benefits of Practicing Jidoka  Defects are not passed on to the next process (the “Customer”)  Equipment breakdown is prevented because problems and their causes become immediately apparent  Machine work is separated from Human work so that team members can operate multiple machines (savings in manpower)
  • 11. © Operational Excellence Consulting. All rights reserved. 11 Tools of Jidoka  Andon  Andon cord  Fixed-position stop  Poke-yoke  Sensors
  • 12. © Operational Excellence Consulting. All rights reserved. 12 What is Andon?  Andon is the Japanese word for “paper lantern”  Refers to any visual display that shows status information  Often combined with an audible signal such as an alarm  Andons are erected to signal when the line is stopped for defects, or difficulties on the line, and as signals for replenishments for parts #1 #2 #3 #4 ANDON BOARD Green = Normal Operation Yellow = Call for Help Red = Line is Down
  • 13. © Operational Excellence Consulting. All rights reserved. 13 Andon Cord  Andon 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
  • 14. © Operational Excellence Consulting. All rights reserved. 14 Fixed-Position Stop  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. Source: Adapted from Lean Enterprise Institute Fixed-Position Stop
  • 15. © Operational Excellence Consulting. All rights reserved. 15 Activity: Andon  In your respective groups, discuss when and where andons can potentially be erected in your work areas to signal the following conditions: 1. When the line is stopped for defects 2. When difficulties are encountered on the line 3. When replenishments for parts are required  List your ideas on the flip chart.  Present your ideas to the class. Time: 10 mins
  • 16. © Operational Excellence Consulting. All rights reserved. 16 What is Poka-Yoke?  Poka-yoke is a Japanese term which means “mistake- proofing” or “error-proofing”  Poka-yoke refers to techniques using low-cost devices or innovations that make it impossible to make mistakes  Poka-yoke helps people and processes work right the first time
  • 17. © Operational Excellence Consulting. All rights reserved. 17 Conditions for Poka-Yoke  The goal is zero defects  Design must be based on actual worksite conditions  Devices must be economical  Devices must be simple with long life and low maintenance
  • 18. © Operational Excellence Consulting. All rights reserved. 18 Three Rules of Poka-Yoke 1. Don’t wait for the perfect poka-yoke. Do it now! 2. If your poka-yoke idea has better than 50% chance to succeed… Do it! 3. Do it now... improve later!
  • 19. © Operational Excellence Consulting. All rights reserved. 19 1 2 3 4 Stop the equipment or line Detect the abnormality Fix or correct the immediate condition Investigate the root cause and install a countermeasure Four Steps of Jidoka
  • 20. © Operational Excellence Consulting. All rights reserved. “Every defect is a treasure, if the company can uncover its cause and work to prevent it across the corporation.” Kiichiro Toyoda, Founder of Toyota
  • 21. © Operational Excellence Consulting. All rights reserved. 21 Activity: Four Steps of Jidoka  In your respective groups, discuss plans for the adoption or adaptation of the four steps of Jidoka in your business/office processes. You may focus your discussion on a pilot line.  List your ideas on the flip chart.  Present your ideas to the class. Time: 10 mins
  • 22. © Operational Excellence Consulting. All rights reserved. 22 Minimize Manual Labor Mechanize Automate Jidoka Current State Future State Developing a Jidoka System
  • 23. © Operational Excellence Consulting. All rights reserved. About Operational Excellence Consulting
  • 24. © Operational Excellence Consulting. All rights reserved. 24 About Operational Excellence Consulting  Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness.  The firm’s mission is to create business value for organizations through innovative operational excellence management training and consulting solutions.  OEC takes a unique “beyond the tools” approach to enable clients develop internal capabilities and cultural transformation to achieve sustainable world-class excellence and competitive advantage. For more information, please visit www.oeconsulting.com.sg
  • 25. © Operational Excellence Consulting. All rights reserved. END OF PREVIEW To download this presentation, please visit: www.oeconsulting.com.sg