In this blog post, we will discuss what Jidoka is, its relationship with Lean Manufacturing and how it is applied. What is Jidoka? Jidioka is a lean manufacturing principle in which machines automatically stop working when they detect an abnormal situation and operators try to correct the fault in order to prevent the recurrence of this error. This principle, also known as autonomisation, is used to prevent or correct malfunctions in production processes. Jidoka literally means automation with human intervention and is one of the cornerstones of the Toyota Production System (TPS). This approach aims to prevent the company from delivering low-quality or defective products. It helps meet deadlines while improving final product quality. Jidoka Basic Principles Jidoka is based on 4 key principles to enable a business to deliver its products flawlessly. These 4 key steps create a stable foundation for a continuous improvement approach and make processes more efficient. Detect anomalies Every piece of equipment must be equipped with the ability to detect faults. In addition, there should be an alert system to report any anomalies, such as product defects, raw material faults and machine malfunctions. Stop production The machines should have the ability to automatically stop operation when any abnormality is detected. They should also be able to stop production manually in case operators notice something below their standards. Correcting the urgent problem After production has stopped, operators should assess the current situation and request assistance. History of Jidoka Jidoka was first implemented in 1896 by Sakichi Toyoda, the Japanese inventor who would become the founder of the Toyota Motor Company. The concept originated as a simple mechanism that stops the machine when a thread breaks on an automatic loom. The mechanism recognised when the thread broke and stopped the machine instantly, thus preventing defects from occurring. The worker operating the machine then had to correct the fault and restart the production process. This revolutionary innovation allowed one operator to manage several machines at the same time, resulting in a huge increase in production capacity. Thanks to its usefulness and efficiency, a British company bought the patent for this invention and provided the necessary funds for the foundation of Toyota. Why is Jidoka Important? Jidoka is important because it is one of the two cornerstones of the production system. The other is the Just-in-Time Production System. Without these two techniques, it is difficult for the Lean approach to survive. The implementation of Jidoka allows businesses to produce high quality products because defective products are automatically identified during the production process. Furthermore, this approach encourages frontline workers to see every problem they encounter as an opportunity for improvement. It promotes a culture of continuous improvement by learning from production defects and implementing solutions immediately. How is Jidoka Applied? Jidoka is based on human beings. For the successful implementation of Jidoka, people must be able to work together with machines. There are 3 basic steps to start Jidoka in Lean Manufacturing: Management Support For the correct implementation of Jidoka within the organisation, a clear definition must be established and communicated to all employees. It must be ensured that everyone is on the same page about what this principle means. This understanding should be consistent throughout the organisation, both from top to bottom and from bottom to top. Readiness Assessments A Jidoka checklist should be created under the guidance of the leader to change the way the organisation operates. The participation of relevant stakeholders should be ensured during the evaluation. Because stakeholders help to better understand the current situation. Implement Practices After identifying and closing implementation gaps, a specific Jidoka project should be planned and initiated with a cross-functional team. One quick way to scale is to install machines or assembly lines with the ability to detect problems and stop production. What are the Benefits of Jidoka? Jidoka has many important benefits: Since defects are automatically detected during the production process, it prevents the production of low quality products and increases the final product quality. Since errors are detected instantly, problems are solved quickly. In this way, there is less disruption in the production process. It enables an operator to manage more than one machine at the same time. Thus, it ensures more efficient use of labour force. Operators and employees see problems as an opportunity for improvement, which supports a culture of continuous improvement. Reduction of defective products reduces rework and waste costs. This reduces overall production costs. Continuous Improvement Software & Lean Production Platform oneri.io is a continuous improvement solution and lean production platform. The platform digitalises the business processes of OPEX, quality, lean, OHS, continuous improvement units and increases the efficiency of the processes. There are 9 modules in our platform and we are constantly working to increase the number of modules. Our current modules are as follows: Employee Suggestion System Kaizen 5S Audit Management Near Miss Reporting Lesson Learned Action Management Help Desk A3 Problem Solving Digital Checklist You can contact us to learn more about oneri.io and its modules or to request a demo.
