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Ninbennoaru Jidoka

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Ninbennoaru Jidoka

  1. 1. Ninbennoaru Jidoka Mind of a human to troubleshoot and correct failures Anand Subramaniam
  2. 2. “Everyone is a genius at least once a year; a real genius has his original ideas closer together.” - Georg Lichtenberg 2
  3. 3. Toyota Production System (TPS) TPS Single Piece Flow Poka Yoke Jidoka People JIT Pull Involve- ment Andons Takt Time Heijunka Sequencing Leveling 3
  4. 4. Jidoka Automation with a human touch = Autonomation Origin of Jidoka - Type G Toyoda Automatic Loom 4
  5. 5. What is Jidoka ?  The Japanese word for “autonomation”  Toyota Motor defines the word as, “investing machines with human intelligence.”  Can be used with machines or people  One of the two main pillars of TPS (Toyota Production Systems)  Machines are designed to stop automatically when a problem is detected or any operator on the line, has the power to stop production 5
  6. 6. Why use Jidoka ?  Lower costs  Increase quality  Reduce lead time  Improve customer service 6
  7. 7. Ninbennoaru Jidoka  Alerts the worker, when a defective item is produced or a machine malfunction has occurred  This allows the problem to be dealt with immediately, preventing the production and passing of defects  Problems and the defects they cause, can be more quickly localised, isolated, and corrected  . 7
  8. 8. Prevention Techniques  Poka Yoke  Visual control of quality  Prevents defects from happening  Andons  Light to signal production line status / attention • Red: line stopped • Yellow: call for help • Green: all normal  Pin-Pan-Pon 8
  9. 9. Jidoka Process Poka Yoke Devices Investigate the Fix or correct Detect the root cause and Stop the immediate abnormality install counter- condition measures 9
  10. 10. “Try to learn something about everything and everything about something.” - Thomas Henry Huxley 10
  11. 11. Good Luck http://www.linkedin.com/in/anandsubramaniam 11

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