Jidoka

Source: www.tera-tps.com.au Document reference cng-2012-6

Jidoka
What is Jidoka?
Jidoka is one of the two pillars of Toyota Production System. Side by side to Jidoka is JIT

What does Jidoka mean? Jidoka: () simply means Human integrated automation or automation with human touch there was no single English word for it initially and now a new English word Autonomation had been generated and used commonly.

A simple example of Jidoka usually illustrated by a machine detects a problem and stop immediately preventing producing bad product.

The principle's origin goes back to 1902 when Sakichi Toyoda invented a mechanism that shut off an automatic loom when a broken thread was detected. This principle had then evolved further.

The principle of Jidoka is simply: "stop and respond to every abnormality." This principle doesnt limit to automated machine only but also apply to all processes, whether it is fully automated, semi-automated or manual. Now the principle also applies to other business processes, IT systems and etc.

The 4 steps of Jidoka:

1. Detect the abnormality. 2. Stop. 3. Fix or correct the immediate condition. 4. Investigate the root cause and install a countermeasure.
The first two steps are together; usually it can be mechanized or automated. Poka-yoke devices are one method to allow a process to detect a problem and stop.

Jidoka Material of Tera Prudent Solutions Pty Ltd (www.tera-tps.com.au)

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Jidoka
Source: www.tera-tps.com.au Document reference cng-2012-6

What is Poka-yoke?
Poka-Yoke (, ) simply means fool proofing literally. It is the defect prevention device either installed in a machine or a mechanism used by the operator. The following examples show how Poka-Yoke device functions When there is a working mistake the material will not fit the tool. IF there is irregularity in the material, the machine will not start. If there is a working mistake, the machine will not start the machining process. When there is step left out, correction is made automatically and machining continues. Irregularities in the earlier process are checked in the later process to stop the defective products. When some step is forgotten, the next process will not start.

The above examples will also apply when there is multiple product produced in the same process, the Poka-Yoke device is able to detect the differences and stop when wrong process was selected. The very common Poka-Yoke on assembly line is the interlocking of torque guns, the interlocking will signal and stop the line when abnormal torque and strip bolts are detected. Beside Poka-Yoke, when an operator detects any defective part, process or other types of abnormality, he must Stop and Call. The team leader must attend to the problem and help to fix the problem before the process restarted again. To activate the Stop and Call, the operator will activate the Andon Call system to set off a visual and audio alarm, so the team leader can attend to the call immediately.

What is Andon?
Andon () in Japanese means traffic light. By it applies to TPS, the meaning is different. There are two major types of Andon, 1. Defect detection Andon, when defect is detected, and the Andon will be activated to draw the attention of the operator. Example, the operator use an air gun to tighten a bolt, the air gun has a Poka-yoke system that detect abnormal torque, when detected, it will set off the Andon, which is a beacon light located close to where the process is performed.

Jidoka Material of Tera Prudent Solutions Pty Ltd (www.tera-tps.com.au)

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Jidoka
Source: www.tera-tps.com.au Document reference cng-2012-6

2. Display Andon or Andon board, the function of display andon is for displaying the production condition and provide overall view of the current condition of the production line, for instant, yellow means abnormal condition detected but not yet stop, whereas red means completely stop. Now usually it getting more digitised by using big LED monitors and they are usually hung over head at the end of the line or wherever visible by everyone.

What is Andon Call System?

When the operator detects any abnormal situation that he couldnt fix, he must pull the Andon Cord or push the Andon button to activate the Andon, so an audio and visual signal will be set off; usually there is an Andon near the process or a flashing yellow signal on the Andon Board. This will draw the attention of the team leader so he can come to assist the operator, if beyond certain time limit, the problem is not fixed, the line will stop and the Andon will change to Red colour.

Step three is to fix or correct the abnormal conditionTo rectify the abnormality so production can resume. It might entail adding a temporary countermeasure to avoid recurrence of the problem. It might mean shutting down production until a broken tool is fixed. At this stage, if the problem is not one off, then short team countermeasure needs to be in place before the production starts again. These decisions need to be made at the lowest possible level of the organization, but when the problem couldnt be fixed, and then it should be escalated to the next level in rank for making the decision. If any short term counter measure is taken, it has to be recorded so follow up action will be in place.

Jidoka Material of Tera Prudent Solutions Pty Ltd (www.tera-tps.com.au)

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Jidoka
Source: www.tera-tps.com.au Document reference cng-2012-6

The last of the four steps is to investigate the root cause of the problem and install a permanent countermeasure. The root cause of the problem will be determined by the 5 Why problem solving method and permanent countermeasures to be developed and follow up with implementation.

Why do you need Jidoka? JIT cant run smoothly or efficiently without Jidoka. Thats a lot of consideration to choose Jidoka as the pillar side by side with JIT. JIT allows good process flow and Jidoka is responsible to ensure no defect is produced by production. It is not only the interlocking system that most people interpreted, but instead it is a complete system of machine and man to ensure no defect is passed on to the next process. Therefore it is important for the supervisors and production engineers to learn about Jidoka and implement them to the production system.

How to implement Jidoka? Tera Prudent Solutions will conduct a 4 hours session to introduce the concept and application of Jidoka. The managers, production engineers and supervisors are required to attend this session. In the second 4 hours visit, an assessment will be made to see what can be done to introduce Jidoka to the shop floor; the assessment will be carried out together with the supervisors and the production engineers. With the result of the assessment, an implementation plan will be developed. Following that, in the next three months, there will be fortnightly follow up with visit to check the progress and provide necessary support for the implementation. Tera Prudent Solution will coach the production engineers to device countermeasures and develop standards for Poka Yoke devices, Andon call system implementation and etc. At the end of the 4th month, Tera Prudent Solution will compile a final report to the management and recommend further supports.

Jidoka Material of Tera Prudent Solutions Pty Ltd (www.tera-tps.com.au)

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