LeanSigma® Facilitator Training

Module 11 – Jidoka – 0 defects

Topics

Jidoka

• Built in Quality – DFSS, DFLS, 3P……………………………………..6 - 7

• Root cause analysis – Ishikawa diagram, 5 Whys, Pareto……8 - 17

• Mistake proofing……………………………………………………………18 - 26

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Lean Sigma has six steps to optimize processes.

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This module will focus on Jidoka aspects of the Toyota Production System.

Jidoka

• “Built in” Quality

• Root Cause Analysis

• Mistake Proofing

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Principlesof LeanSigma®

Justin

Time

JustJustinin

TimeTimeJidokaJidokaJidoka

Process SmoothingProcess Smoothing

Justin

Time

Justin

Time JidokaJidoka

Process SmoothingProcess Smoothing

Without all the elements, the house falls!

Jidoka is a mindset that doesn’t allow errors to pass to customers.

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• Allows processes to automatically detect abnormalities and prevent reoccurrence until corrected.

• Improves productivity by eliminating the need for people to supervise.

• Empowers employees at all levels to:

−Help solve problems

−To make decisions that affect them

−Be accountable for their work

−Improve productivity and quality

Zero defects!

Lean and Six Sigma have approaches to design new processes.

• Design for Six Sigma (DFSS), Design for Lean Sigma (DFLS) and the Production Preparation Process (3P) are approaches to build new processes that are efficient from the start rather than fixing existing ones.

• Because kaizens focus on fixing existing processes, new process design sessions have a different agenda and objectives than kaizens.

• If you can’t say that a process is followed 80% of the time, it’s best to approach it as a new process design.

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Jidoka

• “Built in” Quality

• Root Cause Analysis

• Mistake Proofing

DFLS sessions focus on customer needs.

Steps in DFLS

• Map the high-level process in a SIPOC

• Discuss & prioritize the customer needs (VOC and Kano model)

• Prioritize the process requirements and characteristics

• Construct the new process

Click for IMS notes on DFLS

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Contact your Lean leader if you think a new process design session is needed.

Root cause analysis – understanding problems helps us to solve them.

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Jidoka

• “Built in” Quality

• Root Cause Analysis

• Mistake Proofing

The X’s(Causes)

People Machine Method

The Y

Problem or

Condition

Material Measurement Environment Categories

Because of it’s shape, this is often called a fishbone or an Ishikawa diagram.

The “head” of the fish is a problem or condition.

Material

Products

The X’s(Causes)

People Machine Method

The Y

Problem or

Condition

Material Measurement Environment Categories

The “Y” is a problem or condition:

• Late delivery

• Query responsiveness late

• Customer cancellations

• Supplier data is late

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The “bones” of the fish are causes.

Material

Products

TheProblemThe X’s

(Causes)

People Machine Method

The Y

Problem or

Condition

Material MeasurementEnvironment Categories

The “Xs” or potential causes are organized into these categories:

People Material

Machine Measurement

Method Environment

“X’s” are those factors that may cause the problem or condition “Y”.

Y = f(X1…Xn)

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Examples

What are some common root causes at IMS under each category?

Measurement:

The client’s definition of DAP differs from IMS’ definition.

Key project is not included in PMPs.

People:

People don’t have the skills. Training doesn’t exist. The people responsible for the work don’t have the authority to make changes.

Process:

No documented process exist. There are too many manual steps. There are steps that don’t add any value.

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Examples

What are some common root causes at IMS under each category?

Materials (Supplies):

The supplier’s data was late. The supplier blocked access to some of their data.

Equipment:

The servers went down. A processing error occurred.

Environment:

Unions went on strike. A hurricane caused pharmacies to close. The government enforced new data privacy laws.

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Fishbone diagrams are excellent kaizen tools.

• When process mapping, you will often see a decision point that has a “good” path and an exception path.

• If the percent of exceptions is higher than you would like, use the fishbone diagram to determine the causes.

• Correcting these causes will become part of your action plan.

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Code doctor data

Coding correct?

Bridge data

Fix coding errors

No – 44%

Yes 56%

Why is the coding incorrect?

The Five Whys tool can help you understanding underlying causes.

• Sometimes symptoms of the problem disguise themselves as root causes.

• A way to separate them is the Five Why’s approach.

• It is what it sounds like…keep asking why until the answers are “I don’t care.

• The root cause is the most basic explanation of a problem origin. If eliminated, it would prevent recurrence.

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Pareto tool can help you understand the vital few causes that cause 80% of issues.

• The 80-20 theory says that 80% of the impact comes from 20% of the causes.

• If you can identify the 20% correctly, you’ll be well on your way to fixing 80% of the problems.

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The 80:20 Rule Examples

• 20% of the time expended produced 80% of the results

• 80% of your phone calls go to 20% of the names on your list• 20% of the streets handle 80% of the traffic

• 80% of the meals in a restaurant come from 20% of the menu

• 20% of the paper has 80% of the news

• 80% of the news is in the first 20% of the article

• 20% of the people cause 80% of the problems

• 20% of the features of an application are used 80% of the time

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The most frequent occurrences are always shown on the left. The line above the bar chart shows the cumulative percent of occurrences.

80% of the issues originate here

Pareto charts show root causes as bar graphs.

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Mistake-Proofing goes one step further than root cause analysis.

PreventDefects

Determine Causes

Rank/Sort Defects

Identify Defects

PreventDefects

Determine Causes

Rank/Sort Defects

Identify Defects

Mistake Proofing

C & E Quality Tools Hypothesis Testing

Data Collection Pareto

Check Sheet

Mistake Proofing

C & E Quality Tools Hypothesis Testing

Data Collection Pareto

Check Sheet

Jidoka

• “Built in” Quality

• Root Cause Analysis

• Mistake Proofing

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Mistake-proofing (Poka Yoke) Examples

Parking garages have low clearance. To insure that cars entering the garage will fit, garages are fitted with a go/no-go gauge at the entrance. Hitting the swinging sign or pipe will not damage the vehicle as much as driving into a concrete beam.

This iron turns off automatically when it is left unattended or when it is returned to its holder.

Even bathroom sinks have a mistake-proofing device. It is the little hole near the top of the sink that helps prevent overflows.

Fueling area of car has three mistake-proofing devices: 1. filling pipe insert keeps larger, leaded-fuel nozzle from being inserted 2. gas cap tether does not allow the motorist to drive off without the cap 3. gas cap is fitted with ratchet to signal proper tightness and prevent

over-tightening. Hand washing and Safety Saw videos

Mistake-proofing is especially important in processes with people because we are prone to errors.

• Forgetfulness

• Misunderstanding/miscommunication

• Wrong identification, misread

• Lack of experience/knowledge

• Inattention

• Acting too slowly

• Absence of/poor standards

• Not following standards

• Poor judgment in unusual/emergency situations

• Willful commission

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Error Proofing Techniques

Error Proofing

Mitigate Errors

Detect Errors

Mitigate Errors

Prevent Errors

Eliminate Possibility of

Error

Delegate Necessary Decisions

Facilitate Tasks

Distinguish Tasks

Match Tasks to Abilities

• Reusable code libraries• Child locks on car doors

• Cash register calculates change• Programmed phone numbers• Configuration management of code libraries

• Implementation checklists/scripts

• Color code cables

• Spell checking in a word processor• Thresholds on disk usage / monitoring• Peer reviews & checks

• Auto-correct feature in word processor• UPS• Resilience

Nothing • Customer calls youX

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Not all checks are equally effective.P

luss

es /

Pro

blem

sD

efin

ition

Successive Checks Self Checks Mistake Proofing

Associates check work of previous Associate

Associates check own work before passing to next Associate

Automatic check & prevention of defect

Plus:

Generally effective in catching defects

Problem:

Corrective action can only occur after defect is made

Plus:

Instant correction possible

More palatable than supervisor or peer check

Problem:

Associate may compromise quality or forget to perform check

Plus:

100% inspection usually with no extra time expense

Instant correction

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Mistake Proofing has different levels of intervention.

Shut Down

Signal

Control

Process stop:Cannot proceed until issue is addressed

Pull-down box:Only “X” choices available – must select from choices

Error message:Notification of incorrect data entry by pop-up text box

Mistake Proofing examples are common in our lives.

• Auto-shut-off on gas pumps

• Double-sided car keys

• Auto-flush in public facilities

• What are your examples?

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Characteristics of Mistake Proofing

• Reason for mistake proofing device is clear

• Never fails

• Defective items never passed on

• Low or no cost

• Made with wisdom & ingenuity

• Simple, durable and easy to maintain

• Device idea is transferable to other areas

• Does not interfere with work

• Associate trained in proper use of device

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Mistake Proofing Methodology

1. Identify Defects

Tools: Check Sheet

− Describe the defects

− Determine the defect rates

2. Rank/Sort Defects

Tools: Data Collection, Pareto

− Collect/organize defect rate data

− Create Pareto chart

− Identify “Main Culprit” on which to focus

3. Determine Causes

Tools: C & E, Quality Tools/Hypothesis Testing, Red Flag

− Identify probable causes

− Use C & E and 5 Why’s

4. Prevent Defects

Tools: Mistake Proofing device

− Use associate ingenuity

− Use creativity

− List alternative ideas to eliminate/detect the error

− Create device & test

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Back to EZ Money….

• Finalize your plans for EZ Money with your teams.

• Consider:− Work station layout (5S)

− Standard work (every employee should understand their role.)

− Piloting with a stop watch

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