In the quest for continuous flow and quality, Jidoka is one of the most important tools in your Lean toolbox. With it, you can automate quality checks to identify potential defects in your workflow.
Jidoka is an essential principle in tracking defects and their root cause. But what is it? And how can it help you uphold the quality and speed of your production?
This guide will answer these questions and show you how to apply Jidoka in your business.
What is Jidoka?
Jidoka, also known as autonomation, is a Lean manufacturing method that emphasizes quality control. It is based on the idea of stopping the production line as soon as a defect is detected.
Through Jidoka, you can avoid producing large quantities of low-quality or defective products and minimize their impact on your customers. That way, you can focus on delivering only the best products that meet their expectations.
The goal of this is to ensure that each product meets the quality standards expected by the customer. By stopping the production line, you can take the time to fix the issue and prevent it from happening again in the future.
Brief History of Jidoka
Jidoka was first developed by Sakichi Toyoda, the founder of the Toyota Group. He came up with the idea while working on a loom that would automatically stop when it detected a problem.
This way, he could quickly fix the issue without wasting time or materials. The success of his invention led him to apply the same principle to other areas of production, such as automotive manufacturing.
The Jidoka principle quickly spread beyond Toyota and is now used by companies all over the world as a way to improve quality control.
How does Jidoka Work?
Jidoka relies on automation to stop the production line as soon as a defect is detected. Stopping the line can avoid producing large quantities of defective products.
This way, you can take the time to fix the issue and prevent it from happening again in the future. The goal is to identify and correct problems as soon as they occur, so they don’t become bigger issues.
Jidoka can be applied in several ways, but the most common is to use sensors to detect defects. For example, a sensor can identify when a product is out of specification.
When the sensor detects a problem, it will stop the production line automatically. This way, you can quickly fix the issue and prevent it from happening again.
Jidoka can also be used to monitor the quality of products manually. For example, if you are inspecting a product manually, you can use a Jidoka tag to mark any defects that you find.
The tag will then stop the production line to fix the issue. This way, you can avoid producing large quantities of defective products.
Jidoka Principle: 4 Elements in Lean Manufacturing
There are four basic elements of the Jidoka principle in lean manufacturing. These are detection, stoppage, response, and prevention.
Understanding these fundamental components will help you effectively apply Jidoka in your business. Here’s a breakdown of each component to help you better grasp the Jidoka principle.
Detecting Abnormalities
Every piece of machinery or equipment should have the ability to spot errors and mistakes. An alert system should be in place to signal and notify the concerned personnel about the detected abnormalities, defects, machine failures, and raw material errors.
The goal is to immediately identify problems so that you can fix them before they cause bigger issues. By doing so, you can avoid producing large quantities of defective products.
Stopping Production
Upon detection of potential abnormality, machines should be able to stop automatically to avoid the continuous production of defective products. This way, you can take the time to fix the issue and prevent it from happening again.
Operators should also have the means to stop production manually if they spot a problem. For example, if you are inspecting a product manually, you can use a Jidoka tag to mark any defects that you find.
Taking Actions
With an auto-stop mechanism that halts production, operators can assess the situation and call for immediate assistance when necessary. In addition, the operator should carry out corrective actions within a given timeframe to fix the problem. During this period, they should also decide whether or not to resume production.
Preventing Recurrence
After taking corrective actions, preventive measures must be put in place to ensure that the same problem does not occur again in the future. This could involve training operators on how to use the machinery properly or implementing new quality control procedures.
By taking preventive measures, you can avoid the same problem and ensure that your products are of the highest quality.
Today’s Technology and Jidoka
Jidoka has been around for many years, but it is only recently that technology has caught up to make it more effective. In the past, Jidoka was mostly used in manufacturing and product development.
But with technological advances, Jidoka can now be used in various industries, including healthcare, transportation, and even service businesses.
For example, in healthcare, Jidoka can be used to monitor patients’ vital signs. If there is an abnormal reading, the system can automatically notify the concerned personnel so that they can take action.
In transportation, Jidoka can be used to track the location of vehicles in real-time. This way, you can quickly identify and respond to any potential problems.
And in service businesses, Jidoka can be used to monitor customer satisfaction levels. If there is a drop in satisfaction, the system can automatically notify the concerned personnel so that they can take action.
Technology has made Jidoka more effective and easier to implement in a variety of industries. By taking advantage of today’s technology, you can ensure that your products are of the highest quality and that any problems are quickly identified and corrected.
How to Implement Jidoka
Suppose you’re implementing Jidoka in your manufacturing process for the very first time. In that case, you must create a comprehensive workflow for it—one that will ensure quality and continuous flow in your organization.
Implementation of this requires a company-wide paradigm shift, from overlooking small issues for meeting deadlines to taking full responsibility for ensuring quality at the source. At the heart of this process is the human—the operator who is working on the line.
The key to successful Jidoka implementation in lean manufacturing generally requires four simple steps:
- Demonstrate management commitment: to set manufacturers up for success in administering Jidoka, company leadership must demonstrate a genuine commitment to the initiative by allocating the necessary resources.
- Communicate the Jidoka message: once management has made its commitment, Jidoka should be communicated throughout the entire organization so that everyone understands its purpose and objectives.
- Conduct Readiness Assessment: to ensure successful Jidoka implementation, a comprehensive readiness assessment is recommended. The purpose of this assessment is to identify any potential obstacles that could impede the Jidoka process.
- Execute Practical Applications: After the Jidoka message has been communicated and the readiness assessment is complete, it is time to put Jidoka into practice. This will involve identifying Jidoka opportunities and implementing Jidoka solutions.
By following these steps, you can ensure that your organization is ready to implement Jidoka and that you are taking full advantage of today’s technology. In addition, doing so will help you improve your products and services and better meet your company’s needs.
Implement Jidoka with DATAMYTE
As the leading quality management software solutions provider, DATAMYTE has the right software to help you implement Jidoka in your organization. The DataMyte Digital Clipboard is a workflow automation software that can help teams implement Jidoka by developing a digital workflow that will help them respond to issues faster and collaborate better.
With our Digital Clipboard, you can:
- Create Jidoka-centric workflows.
- Automate Jidoka processes in real-time.
- Monitor critical quality parameters in real-time.
- Automatically notify operators when there is a problem.
- Take corrective actions quickly and prevent problems from happening again
- Implement new quality control procedures easily and efficiently
- Gather data and information to improve your Jidoka process
- And more!
Book a demo with us today to learn more about how the DataMyte Digital Clipboard can help you implement Jidoka in your organization. We would be happy to provide a personalized demo and show you how our software can help you take full advantage of Jidoka.
Conclusion
Jidoka is a powerful Lean tool that can help ensure quality and continuous flow in your organization. By implementing this principle into your operations, you can take advantage of today’s technology to improve your products and services.
