APO E LEARNING PROGRAM “INTEGRATING LEAN

MANUFACTURING SYSTEM AND INDUSTRY 4.0

CONCEPT”
Module 7: Preventing failure with Jidoka
The Jidoka concept
Poka Yoke
Industry 4.0 application
Quiz

Slide 1
Jidoka
In Jidoka, machine and processes are designed and operated with
feature that it will automatically stop if a defect is detected. Which also
refer as the combination of automation and mistake proofing or so
called the automation with a human mind.

Automation
with a human
mind

Slide 2
Jidoka
Toyota experience with Jidoka concept could trace from the automatic
weaving machine invented by Sakichi Toyoda which will stop if any
threads broke. Without the automatic stop function, the weaving
machine will continued to produce even those that’s a broken threads
and results produced reject.
The Jidoka objectives shall consist of reduce cost, control of over
production and show respect for people.

Control
Reduce cost
overproduction

Show respect
for people

Slide 3
Jidoka – Reduce cost
The application of Jidoka enable workers to fully optimized without
allocated one worker for one machine, whereby machine will stop
whenever defect produced which prevent additional defect and lead to
reduce potential cost in reject or sorting.

Automation: to ensure the part Automomation

produce automatically without
the aid from an worker
Mistake proofing: To ensure the
machine produce within
specification and able to stop if
any out of specification detect
• Machine automatically stops
work, and operator is alerted
through signal such as Andon
• Jidoka improves quality and
empowers the operator
• Allows operator to manage more
than one machine at one time

Slide 4
Jidoka – Control of over production
Jidoka enable machine not only designed to stop when defect detect
but also stop whenever the require quantity achieved. Therefore the
machine will produce exactly according to the Kanban required
quantity which lead to precision control on work in progress and final
inventory. Automatic stop
when required
quantity achieved

Slide 5
Jidoka – Show respect to people
By stopping defective process automatically with Jidoka feature, the
worker will able to real time identify the problems which helping
worker to understand the conditions and improvement their ability to
identify the root causes and implement effective counter measures.

Problem Solving steps

Factors to consider
1. Stopping the line
1. Build trust in workforce
(By or signal from
2. Foster collaborative nature
Jidoka)
for problem solving
2. Understand nature
3. Do not respond to mistake
of problems
with punitive measures
3. Immediate action
4. Understand the basic
4. Root causes
problem solving tools
analysis
5. Take time to fix the
5. Corrective action
problem correctly
(e.g. Poka Yoke)

Slide 6
Jidoka
In order to fully implement the Jidoka principle, following six key
concepts shall be consider:-

Slide 7
Jidoka – Quality at source
Quality inspection at various stage of processes remain the most
popular approach among small and medium enterprise, however
allocation of inspector only result sorting defective products from the
good one, which the quality control inspector have no effect on the
quality of the product. Therefore to ensure quality at source consider
the better and more cost effective approach. In ensuring quality at
source, following element shall be consider:-

Standard Successive
Self check
work checks

Visual Continuous
Poka Yoke
management improvement

Slide 8
Jidoka - No defects passed forward
The processes owner shall responsible to ensure all received products
(or work in progress WIP) from the upstream and those completed the
current processes shall compliance with the
requirements/specification before proceed to the next process. As if
any defects passed forward will disrupt the next process which
eventually affect the implementation of one piece flow, Kanban and
just in time.

Slide 9
Jidoka - Separate man from machine
With combination of standard work and autonomation concept which
the operator could run more than one machine at a time. As the
machine capable to self inspect and prevent or alarm any defects
produced, the operator will be freed up from monitoring single
machine operation but manage operation of multiple machines

Slide 10
Jidoka - Multi process handling
Where separation of man and machines enable operator to run more
than one machine at the same time, Multi process handling
incorporates cellular flow where multiple processes are combine into a
single operation.

Packing Labeling

Inspection Cutting

Production Assembly

Slide 11
Jidoka - Self detection of errors to prevent defects
Self detection of errors to prevent defect refer to the popular “Poka
Yoke” which also mean “Inadvertent error (Poka)” and “prevention
(Yoke)”
Poka Yoke means implementing simple low cost devices that either
detect abnormal situation before they occur, or once they occur, stop
the line to prevent defects. Implementation of Poka Yoke could
significant reduce workers physical and mental burden of constantly
check for the common errors for long period of time

Slide 12
Jidoka - Self detection of errors to prevent defects

Simple Contact sensor

Limit switch,
touch sensor, etc.
Low maintenance
Good
Poka Noncontact
Yoke High reliability sensor
Metal passage
detector pressure
Low cost
gauge, etc.

Slide 13
Jidoka - Stop and fix
Whenever detected defects, the process shall stop to investigate and
fix the problem before resuming operation. Most small and medium
enterprise may practiced continue production even those detected
problems and assume to fix the problem later to prevent any line
stoppage, nevertheless stop and fix the problem immediately proven a
more cost effective solution in the long term.

Slide 14
Jidoka - Industry 4.0 application
With Industry 4.0 technology, plug and play and distributed system will
enable self optimizing and machine learning behavior on possible type
of defects and RFID tag from e Kanban could communicate with
machine on quantity require to produced. This results in robust
changeover according to production schedule and situation when
needed to stop for defected problems

Slide 15