A useful article for anyone who wants to understand the concept. Jidoka or Autonomation means “intelligent automation” or “humanized automation”. Just what is Jidoka and how can it help your business ensure built in quality through the prevention of problems as well as increasing productivity. The concept of Jidoka is “Automatic detection of problems or defects at an early stage and proceed with the production only after resolving the problem at its root .

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Development of Jidoka Jidoka was invented by Sakichi Toyoda Founder of the Toyota Group in by a simple device that could stop the shuttle on an automatic loom if the thread broke. Jidooka I understand it, the origins of jidoka and of a lot of the Toyota story lie in the automatically stopping loom back in the days of Toyoda weaving — if you have that story, it would be a nice addition here!

Since equipment stops when a problem arises, a single operator can visually check and monitor many machines. You could make the yarn stronger, but this would change the quality of the fabric.

JIDOKA: the concept | Logistics World’s Blog

Many people I worked with at Toyota did not understand this and it is not the easiest concept to teach. The 5 steps to building jidoka equipment are for machine process second type, narrow application. Making things better through lean thinking and practice.

There may also be issues with the process that may not lead to quality problems, or at least not immediately. When the yarn breaks, it quickly turns into a defect. It is about building quality into a process rather than inspecting for it at the end of the process. Of course, if you need to stop the process for a set-up, you have to stop it. In this case, the process should be stopped too.


The benefit of jidoka is its utilization. This was a revolutionary innovation because it allowed one operator to run more than one machine at a time and increased the production capacity significantly. Jidoka comes from the Toyota Production system and is very often forgotten even while it is one of the most important principles of lean. Other Lean tools use various aspects of visual management to highlight abnormalities, consider 5S ; we identify the locations for tools, components and work in progress, if we see things that are not in their allocated place we have seen an abnormality and should take action.

The 7 steps are a subset of the 10 steps of full automation. The way I know it and the way I will describe it in more detail below is that jidoka means a process stops automatically if there are any irregularities.

What is Jidoka?

Stopping the process in case of trouble is essential for a good production system. Other tools such as Kanban will also quickly highlight problems, why have these products been moved without Kanban authority?

In my second post on jidokaI will talk a bit about the practical approach, and also get a little bit philosophical. Common benefits obtained by its implementation are:. This meant that a single operator could be put in charge of numerous looms, resulting in a tremendous improvement in productivity. In the latter case, you do not get any parts at all, but instead a long delay and a potentially significant repair bill as well as an injured employee.

This site uses cookies: This eliminates the need for operators to continuously watch machines and leads in turn to large productivity gains because one operator can handle several machines, often termed multiprocess handling.

Jidoka; autonomation, line stop, Poka yoke and visual management are very important to ensure quality at source or built in quality and to protect our customers and businesses; used correctly Jidoka will drive improvement through all aspects of our business.


So through a sometimes initially painful jiodka of line stops we start to remove problems from our process, within a short period of time the jidokq of line stops begin to reduce as problems are removed and productivity begins to improve as root causes of problems are removed.

We then need to ensure that any process documentation is updated to incorporate the changes and that we communicate those changes across similar processes and products to spread the learning.

Overproduction of goods Wasted time during manufacturing at the machine Wastage of time during transportation of defected material from one place to other Waste of time during defective piece cnocept Waste of inventory The purpose of Jidoka implementation is to diagnose the defect immediately and correct it accordingly.

Common benefits obtained by its implementation are: Jidoka is about quality at source, or built in quality; no company can survive without excellent quality of product and service and jidoka is the route through which this is achieved.

This can also be seen as an abnormality, as the process is not working normally, but rather being prepared. Could you give examples of where this is not possible.

Having a human watch over the machine constantly is both demanding and error-prone.

This concept also helps in sequential inspection of components and ultimately good quality products are produced and also not much burden of final inspection is put on concpet shoulders of worker.

This gave the possibility to one operator to operate several looms and not to stand only at one machine and to watch if something goes wrong. The common causes of defect are:. Your email address will not be published.