Summary Jidoka

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 :

1. To Guarantee the production, achieve the best quality.
2. To Simplify  manpower production.
3. 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: 

1. Detecting the strange things
2. Stopping
3. Repairing  immediate mistake
4. Investigating the main cause

There are two lean tool in Jidoka:

1. Poka Yoka
2. 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:

1.  Reduce or prevent potential mistake to 100%
2.  No chance to make mistake
3. Prevent from defect or damage from the resource 
4. Reduce dependent of manpower to detect the mistake
5. 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