introduction to jidoka november 2016
TRANSCRIPT
Jidoka Introduction
Thinking win, Win, WIN
Introduction to JidokaDefinitions
Marek Piatkowski – November 2016
Jidoka Introduction
Thinking win, Win, WIN
Introduction - Marek Piatkowski Professional Background
Toyota Motor Manufacturing Canada (TMMC) - Cambridge, Ontario from 1987-1994
TPS/Lean Transformation Consulting - since 1994 Professional Affiliations
TWI Network – John Shook, Founder Lean Enterprise Institute (LEI) – Jim Womack Lean Enterprise Academy (LEA) – Daniel Jones CCM/CAINTRA – Monterrey, Mexico SME, AME, ASQ, CME
Lean Manufacturing Solutions - Toronto, Canada
http://twi-network.com
Jidoka Introduction
Thinking win, Win, WIN
What is Jidoka? Jidoka is one of the two pillars of the Toyota Production System
along with Just-in-Time.
There are two principles of Jidoka: 1. Separate man’s work from machine’s work
Jidoka is sometimes called Autonomation gives equipment the ability to distinguish good parts from bad autonomously, without being monitored by an operator
2. “Stop the Line and fix the problem” Stop and notify of abnormality - never let a defect pass to the next
station
Stability
GOAL: Highest Quality, Lowest Cost, Shortest Lead Time
1. Stable Manufacturing Processes2. 100% Quality Parts
Heijunka Standardized Work Kaizen
Just-in-Time Jidoka
Stop the lineand fix
the Problem
Separate man’s work from
machine’s work
ContinuousFlow
Takt Time
Pull System
The Toyota House
Jidoka Introduction
Thinking win, Win, WIN
Jidoka - Autonomation Jidoka is a methodology to provide machines and operators with
the ability to detect when an abnormal condition has occurred and immediately stop the work.
The concept of Jidoka originated in the early 1900s when Sakichi Toyoda, founder of the Toyota Group, invented a textile loom that stopped automatically when any thread broke.
Jidoka is Autonomation, meaning automation with human intelligence:
Jidoka frees the operator from watching the machine The need for operators not to continuously watch machines leads
to large productivity gains because one operator can handle several machines, often termed multiprocess handling.
Autonomation allows us to separate Operator’s work from Machine’s work
Jidoka allows the operation to have a build-in quality at each step of a process, so the Operator does not have to “watch” the machine or the operation
Jidoka Introduction
Thinking win, Win, WIN
Jidoka Principles Jidoka also means – never letting a defect pass to the next station “Stop the Line – Fix the Problem” Jidoka highlights the causes of problems because work stops
immediately when a problem first occurs - this leads to improvements in the processes that build in quality by eliminating the root causes of defects.
Jidoka Steps: Detect the abnormality Turn on the Andon – or Stop Fix or correct the immediate condition Investigate the root cause and install a countermeasure
Jidoka Introduction
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Elements of Jidoka Andon – a visual control mechanism that displays the current state
of work Green – status OK Yellow – call for help Red – Line stopped
Fixed-Position Stop – a position on the assembly line where a zone process is completed. It is at these positions that the line will stop should an abnormality be not corrected on time – at the end of Takt Time.
Line-Stop Cord – a mechanism, usually a rope, that a worker may pull to signal the need for assistance and which will stop the line if the problem is not fixed under Takt Time.
Poka-Yoke - a low cost, highly reliable devices, used in the Jidoka system ,that will stop processes in order to prevent the production of defective parts.
Jidoka Introduction
Thinking win, Win, WIN
Fixed-Position Stop System In the Fixed-Position Stop System if an operator anywhere on the
assembly line notices an abnormality can stop the production flow by pulling a rope or by pushing a stop button.
Pulling the rope or pushing a stop button lights up a “number” or a “light” on a large Andon signboard to call the Supervisor's attention to the problem.
This action does NOT STOP the Production Line – it just issues a warning
The Operator continuous working – finishing the rest of his Standard Work
The Supervisor rushes to the station indicated and helps to correct the problem.
When a problem has been resolved, the Supervisor pulls the rope again to prevent the Line from stopping
The Line STOPS ONLY when the problem is not resolved and the product (a car) has reached the Fixed-Stop position
Jidoka Introduction
Thinking win, Win, WIN
Poka-Yoke Poka-Yoke is a Japanese word translated as “foolproof mechanism” Poka-Yoke helps operators work easily and at the same time it
eliminates troubles associated with defects, safety, mistakes in operation, and so on without requiring undue attention
Even if the Operator makes a mistake, Poka-Yoke will prevent defects:
will not start the machine or it will stop the machine.
While Poka-Yoke or foolproof mechanism can eliminate defects, further consideration must be given to the process capability of machines where numerous factors can effect quality
Jidoka Introduction
Thinking win, Win, WIN
Two Types of Poka-Yoke
1. Warning - Indicates an error situation requiring intervention
2. Control – Stops production, prevents mistakes
It this Poka-Yoke or NOT?
It this Poka-Yoke or NOT?
Jidoka Introduction
Thinking win, Win, WIN
Jidoka
There are four steps in developing Jidoka:1. Minimizing manual labour - Manual labour simply means that all work is
being done by hand. This makes sense only when the labour costs are cheap and/or the manual work can be done very quickly.
2. Introduction of mechanization - Mechanization means leaving part of the manual operation to a machine. The work is shared between the Operator and the machine.
3. Automation - In this step all manual labour is taken over by the machine. The Operator just loads the workpiece into the machine and presses a switch to start the machine. The Operator can leave the machine alone, but there is no way to know whether the machine is producing a good or a bad part.
4. Jidoka (Autonomation) - The operator simply presses the ON switch and leaves the machine to do the processing. The machine will detect when a problem has occurred and will automatically shut itself OFF. In addition to defect detection Jidoka sometimes includes auto-input and auto-output. This completely eliminates the need for the Operators participation
Jidoka Introduction
Thinking win, Win, WIN
Changing the World. One Kaizen at a timeThis presentation is an intellectual property of W3 Group Canada Inc.
No parts of this document can be copied or reproducedwithout written permission from:
Marek PiatkowskiW3 Group Canada Inc.iPhone: 416-235-2631
Cell: 248-207-0416
[email protected]://twi-network.com
Jidoka Introduction
Thinking win, Win, WIN
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