JIDOKA

Agile and Lean Manufacturing (IM-515)

Dr. M Fahad

Jidoka

Jidoka

Automatic Working
Autonomation

Automation with a human touch

Jidoka

Jidoka
Providing machines and operators the ability to detect when
an abnormal condition has occurred and immediately stop
work.
Enables operations to build-in quality at each process and to
separate men and machines for more efficient work.
Allows equipment to perform without human intervention or
assistance

Jidoka: Steps

Following are the four main steps of Jidoka

1. Detect the abnormality
2. Stop the process/equipment
3. Fix or correct the immediate condition
4. Investigate the root cause and install a countermeasure

Jidoka: Tools

Prediction/Detection

Poka Yoke

Signaling/Stopping

Andon

Poka Yoke

Poka

Inadvertent Mistake That Anyone Can Make

Yoke

To Prevent or Proof

Poka Yoke

A device/mechanism which prevents a process from

making

Mistake Proofing
Mistake Prevention

an error
passing a defect to user

Poka Yoke
Error

Defect

Poka Yoke

Effects:

Sensory Alert/Warning

Forced Control

Shutdown

Outcomes:
Prevention

Detection

Have triggers that depend on the operator to

notice and respond to them.
Forced control and shutdown effects both
have automatic triggers.

Poka Yoke:Devices

Counters/Timers

Counters look at the occurrence of events

Usually triggered by one of the other types of sensors
Can be programmed to shut down the process if a set number of events do not
occur or if too many events do occur
Timers can shut down the process if processing time or activity time does not
meet or exceeds a preset level.

Applications

Ensuring the proper number of events occurred.

Preventing failure of equipment or a component
by timing usage.

Poka Yoke:Devices

Limit Switches
Electro-mechanical devices that are activated or deactivated when an object comes
in contact with them.

They are used to detect the presence or absence of an object.

Applications

Proper positioning of safety devices.

Detection presence or absence of object.

Positioning of a work piece.

Poka Yoke:Devices

Proximity Sensors
Emit a high-frequency magnetic field and detect an upset in the field when an object
enters it.

They can be used to detect the presence or absence of an object.

Applications

Sensing of tank or bin level.

Confirmation of part or object passage.

Detection presence or absence of object.

Positioning of work piece.

Poka Yoke:Devices

Laser Displacement Sensors

Focus a laser beam on a target and use the reflectance of the beam off the target
to determine the presence of a target and distance to it.

Applications

Measuring distance.

Detection of presence or absence of a feature.

Confirmation of part or object passage.

Positioning of work piece.

Poka Yoke:Devices

Vision Systems
Use cameras to look at a surface and then compare the surface viewed to a
standard or reference surface stored in the computer.
They can be used to detect the presence or absence of an object, the presence of
defects, or to make distance measurements.

Applications

Missing parts in an automated assembly line.

Poor quality surfaces or components.

Correct orientation of parts or labels.

Ensure correct relative position.

Color detection.

Detecting incorrect product.

Poka Yoke:Devices

Ultrasonic Sensors
Ultrasonic sensors emit high frequency radio waves and detect the reflectance of the
wave off an object.
They can be used to detect the presence or absence of an object or to make
distance measurements.

Applications

Sensing of tank or bin level.

Confirmation of part or object passage.

Detection presence or absence of object.

Positioning of work piece.

Measuring distance.

Poka Yoke:Devices

Process Variables Measurements

Temperature
Pressure
Mass/Weight
Viscosity
pH
Humidity

Poka Yoke: Examples

Andon

Jidoka: Benefits

Adds human judgment to automated equipment

Helps in detecting a problem earlier

Minimizes poor quality

Makes the process more dependable

Allows worker to perform value adding operations

Leads to Zero Defects/Quality Control