JIDOKA
At this time I want to explain
about JIDOKA
What is jidoka?
Jidoka is combination of two words
namely automation and autonomous, so jidoka means autonomation. Jidoka terms
used in lean manufacturing meaning “ automation
with human touch “
Automation is the effort to
takeover of man power/ labor by machines, which are necessary to do the easy
job and repetitive - action.
Sometimes, people make mistake which is call human error. This mistake can impact on product quality or
affect to safety of the operator. There's a phrase in Lean of " Don’t ask human to do
machine’s job.”
Autonomous, actions (human) done by people with awareness
and mind, is able to detect and act if there are irregularities or potential
production defects, so that the line can be immediately terminated.
Jidoka is an important component of
lean manufacturing strategy to reach high quality product.
The purpose of Jidoka, namely :
- To Guarantee the production, achieve the best quality.
- To Simplify manpower production.
- To Prevent down time due to abnormalities in the production process.
Jidoka concept is to immediately
stop the work / process when found an error in the process, so that defects can
be avoided.
"Stop production so
that production never has to stop" (Toyota)
Jidoka, first used by Sakichi
Toyoda (Founder of Toyota), is one of two pillars of the Toyota Production
System along with Just In Time.
Principle of Jidoka can be divided
into some simple steps:
- Detecting the strange things
- Stopping
- Repairing immediate mistake
- Investigating the main cause
There are two lean tool in Jidoka:
- Poka Yoka
- Andon or Visual Control
POKA-YOKE
Poka Yoka is a technic to overcome
and avoid simple mistake caused by Human error in work side by direct
preventing from the root cause of mistake so that it doesn’t create new mistake.
Poka yoke works maximally in
preventing the mistake, not to find the mistake.
The purpose of Poka Yoke Method is
to:
- Reduce or prevent potential mistake to 100%
- No chance to make mistake
- Prevent from defect or damage from the resource
- Reduce dependent of manpower to detect the mistake
- Zero Defect
ANDON
Andon is board (Panel) equipped with light signal to indicate whether there are the problem.
There are three kind Light of
Andon, namely :
1. Green light indicates that the process work properly
2. yellow light indicates that there is potential problem
3. Red light indicates that the production will stop
immediately (usually connected to alarm)
This is the evolution toward
Jidoka. The picture shows us the process
of controlling product from traditional (old- fashioned ) way to jidoka system.
The first picture that everything is being controlled by
operator, and than 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.
Created By :
Mutia Sabrina Mardias
2234.14.040
D.III. MLM 2014
