JIDOKA

 SUMMARY JIDOKA

What is JIDOKA?

JIDOKA known as Automation with Human Intelligent/Human Touch which means the machine was given the ability to be able to mark off the bad over the good without being monitored by the operator.
JIDOKA will facilitate human in providing detection and warning in case of errors , at the same time to prevents the errors by human activities undertaken (Human Error).

JIDOKA Evolution

 

In the first picture we are know that everything is being controlled by operator, and second picture the machine start the job itself and the operator just watch how it goes, and the last picture the machine do the job itself without being control by operator around the machine. The operator actually still control the machine but only by Andon board. The operator just watch over the Andon board that will light up the number if the machine detect the errors.

 

-Andon Board-

TOYOTA Production System Concept

1. " Highlighting/View of the problem"
2. "Quality must be built during the manufacturing process"

JIDOKA is basically combine the quality checks into every single step of the production process by ensuring that all processes visible. JIDOKA also helps to ensure that any abnormalities/errors can be fixed immediately. 

TOYOTA Mistake-proofing

 

Known as poka-yoke, this principle is a simple, yet creative and reliable way to reduce errors and maintain quality. So basically in this principle items are clearly labelled so that they can be found and used by everyone just as easily.

 

A Simple Set of JIDOKA Rules

 

 

1. Discover problem
2. STOP
3. Fixing the problem
4. Investigate the root cause of the problem

Within companies such as Toyota line stop is a way of life, if an operator detects a problem they pull a cord or push a button to stop the production line at the end of that production cycle. 
If it such a simple or easy error then the operator will fix it themselves and restart the line, otherwise they will call support that requires to solve the error if it such as a complicate one.

many western companies just fear for a loss in productivity by JIDOKA because for only minor problem the machine will being stopped constantly. But, actually through JIDOKA we don’t just stop the process, we highlight the problem, correct it and then tackle root cause to prevent the problem ever happening again. JIDOKA  actually improve the standardization of production process by remove root causes.

 

"we are seeing a race against the clock with Logistics" - Tom Kloza

This blog was created by:

Siti Annisa Nuryati

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D3 MLM 2014