JIDOKA

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JIDOKA

• Mac Hu

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What Will Be Covered

• What is Jidoka?
• Role of Jidoka
• How your firm can benefit from Jidoka
• A closer look at Jidoka
• How it works

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What Will Be Covered

• Real World Examples
• Exercises
• Summary
• Reading, References, Info Lists

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What is Jidoka?

• Automation with a human touch
• Practice of stopping a manual line or process
  when something goes amiss
• Also known as Autonomation

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What is Jidoka?

• Quality built-in to the process
• First used by Sakichi Toyoda at the beginning of
  the 20th century
• A pillar of the Toyota Production System

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Role of Jidoka

• Autonomation is an important component of Lean
  Manufacturing Strategy for high-production, low-
  variety operations, particularly where product
  life cycles are measured in years or decades.

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How Your Organization Can Benefit From Jidoka

• Jidoka helps to detect a problem earlier
• Jidoka avoids the spread of bad practices
• A level of human intelligence is transferred into
  automated machinery

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How Your Organization Can Benefit From Jidoka

• No defective products produced
• Tremendous improvement in productivity

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A Closer Look at Jidoka manufacturing high
quality products

• The word traces its roots to the automatic loom
  invented by the founder of the Toyota Group
• A built-in device for making judgments
• Opposed to a machine that simply moves under the
  monitoring and supervision of an operator

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A Closer Look at Jidoka -- Concept
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A Closer Look at JidokaAutonomation
clarification

• Automation vs. Autonomation
• (???) (???)
• Labor Reduction vs. Quality Improvement
• Increases technicality vs. Reduces technicality

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How It Works

• Adds human judgment to automated equipment
• Minimizes poor quality
• Makes the process more dependable
• Gives the employee responsibility and authority
  to stop production

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In The Real World

• If Jidoka is not practiced then you can not
  attain a very high level quality and productivity
  will suffer since you are not catching problems.
  
• Mr. Tomo Harada, 35 years with Toyota Motor
  Corporation in a variety of management positions

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In The Real World

• One of NUMMIs basic concepts is that quality
  should be ensured in the production process
  itself. This concept, known as Jidoka, means not
  allowing problems to pass from one work station
  to the next.
• Production System Statement, NUMMI (New
  United Motor Manufacturing, Inc.)

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Exercises

• Q1 What is Jidoka?
• Q2 How would your organization benefit from
  implementing Jidoka?
• Q3 What is the role of Jidoka?

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SUMMARY

• Jidoka, also known as Autonomation, means
  automation with a human touch.
• Jidoka, first used by Sakichi Toyoda, the founder
  of Toyota, is one of two pillars of the Toyota
  Production System.
• Jidoka is an important component of Lean
  Manufacturing Strategy for high-production, low-
  variety operations.

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SUMMARY

• Jidoka helps to detect a problem earlier and
  avoids the spread of bad practices.
• Jidoka results in high-quality products and makes
  improvement in productivity.
• Autonomation is different from automation.

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Reading List References

• Strategos, Inc.
• http//www.strategosinc.com/
• Toyota Motor Corporation
• http//www.toyota.co.jp/
• FredHarriman.com Kaizen Basics
• http//www.fredharriman.com/
• Art of Lean, Inc.
• http//artoflean.com/

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Reading List References

• New United Motor Manufacturing, Inc.
• http//www.nummi.com/
• MONDEN, YASUHIRO, Toyota Production System, Third
  Edition, Industrial Engineering Management
  Press, Atlanta, Georgia, USA, 1998.
• OHNO, TAIICHI, Toyota Production System- Beyond
  Large Scale Production, Productivity Press, 1988.

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For More Information

• Automotive Manufacturing Production, July 2001,
  v113 i7 p64.
• The Financial Times, December 13, 2001, p13.
  Imai, Masaaki. Kaizen. New York McGraw-Hill,
  Kaizen Institute, 1986.
• The Just-In-Time Breakthrough. Rath Strong,
  Inc. John Wiley Sons, Inc., 1988.
• Management Review, June 1997, v86 i6 p36.
  Sepehri, Mehran. Just-In-Time, Not Just In
  Japan. American Production Inventory Control
  Society, Inc., 1986.