Toyota Production System Jidoka: Stopping Production, a Call Button and Andon.

Jidoka is a key concept in the Toyota Production System (TPS), and it is used to prevent defects and improve quality. Jidoka is a Japanese term that means “automation with a human touch” or “autonomation”.

The basic idea of jidoka is to design machines and processes so that they can detect and stop themselves when a problem occurs. This prevents defective products from being produced and allows problems to be addressed quickly and easily.

[Toyota Production System] Jidoka: Avoiding Simple Mistakes Through Poka-yoke Device

There are two main types of jidoka:

Mechanical jidoka: This is where the machine itself detects the problem and stops. For example, a machine might have a sensor that detects if a part is out of spec, and it will stop the machine if the part is not within tolerance.
Human jidoka: This is where the operator detects the problem and stops the machine. For example, an operator might be responsible for inspecting parts as they are produced, and they will stop the machine if they see a defect.

Jidoka is a powerful tool for improving quality and preventing defects. It is one of the key principles that has allowed Toyota to produce high-quality vehicles at a high volume.

Examples of jidoka in action at Toyota:

In a Toyota car factory, there are sensors on the machines that detect if a part is out of spec. If a part is out of spec, the machine will stop automatically.
Toyota operators are trained to inspect parts as they are produced. If an operator sees a defect, they will stop the machine and notify a supervisor.
Toyota has a system called Andon, which is a visual signaling system that allows operators to quickly communicate problems to supervisors.

Jidoka is not just about stopping machines when problems occur. It is also about preventing problems from happening in the first place. This is done through a process of continuous improvement called kaizen.

Kaizen is a never-ending process of identifying and eliminating waste. When a problem is identified, it is investigated to find the root cause. Once the root cause is found, it is addressed to prevent the problem from happening again.

Jidoka and kaizen are two of the key principles that have made Toyota one of the most successful companies in the world. They are also principles that can be applied to any business, regardless of size or industry.

Here are some of the benefits of jidoka:

Improved quality: Jidoka helps to prevent defects by detecting and stopping problems early.
Reduced waste: Jidoka helps to reduce waste by preventing defective products from being produced.
Increased productivity: Jidoka can help to increase productivity by reducing the time and effort spent on identifying and fixing problems.
Improved safety: Jidoka can help to improve safety by preventing machines from operating when there is a problem.
Increased employee satisfaction: Jidoka can help to increase employee satisfaction by giving them the power to stop machines and fix problems.