Jidoka

CONFIDENTIAL Document Number : GBE-KPO-2-012-00

Revision Number : 06
Effective Date : 29 April, 2013
 Document Title Document # : Revision
GBE-KPO-2-012-00 06
Jidoka
Document Owner :
Prakash Subramaniam

REVISION HISTORY

Revision Description of Change Writer/Reviser Effective Date

02 Document formatted as per DMS policy Prakash Subramaniam December 11, 2008

03 Complete Review of the Document Prakash Subramaniam June 02, 2009

04 Complete review of document Prakash Subramaniam January 16, 2012

05 Document updated with the latest format Chandran Bendaiya December 20, 2012

• Complete document review

06 Prakash Subramaniam April 29, 2013
• Added slides 36, 38 and 39 on Poka Yoke

2COMPANY Jidoka
CONFIDENTIAL Printed copies are uncontrolled copies.
GBE-KPO-2-012-00
Verify revision Rev.06
and approvals in the FMS Document Management System on ShareNet.
Table of contents
Contents Slide(s) Contents Slide(s)
• The Flextronics Lean Enterprise (FLE) 4 • Zero Defect Approach – Link to Jidoka 30 -31
• Overview & Scope 5 • Source Inspection (1st Source Inspections) 32
• Founder & Technical elements of TPS 6-7 • Poka Yoke 33-35
• Definition of Jidoka 8-10 • Poka Yoke for missing spring 36
• Jidoka is Futuristic Quality System 11 • Poka Yoke to avoid wrong mixed assembly 37-38
• Why Jidoka ? 12 • Poka Yoke for Audio Testing 39
• Looms to Cars 13
• Jidoka Process 14
• Application of Jidoka 15-16
• Andon 17-20
• Andon Cycle and examples 21 - 25
• Autonomation 26
• Example of Jidoka – Hanedashi 27
• Autonomation Example – Functional Tester 28
• Benefits of Autonomation 29

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 The Flextronics Lean Enterprise (FLE)

Adding Value and Eliminating Waste

FLE
i. Takt Time
Production i. Stop @
Abnormality
ii. Single Piece
Flow JIT Jidoka
iii. Pull ii.Autonomation
Production

i. Level Loading Heijunka ii. Sequencing

5S+1, VSM, Supermarkets

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Overview & Scope …

Just-In-Time

The Toyota Production System is a house with two pillars. One pillar represents Just-in-time (JIT), and the other pillar
the concept of Jidoka. The house will not stand without both pillars. We therefore need to take a holistic approach and
give equal importance to both JIT and Jidoka. JIDOKA is key to making the entire system work.

Jidoka itself can be further split into a) Stop at an Abnormality and b) Autonomation. Stopping @ an Abnormality will
ensure that the process does not continue even when bonepile is being generated while Autonomation (remember this
as Automation with a human element) could Poka Yoke further defect generation … both of these ultimately help in
keeping the bonepile down and thereby the profits up.

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Founder of Jidoka

Taiichi Ohno (1912~1990)

Taiichi Ohno, worked for a small Japanese automobile manufacturer named

Toyota. Toyota was under extreme pressure to cut costs and increase efficiency.
Ohno went to the United States to study Ford’s assembly lines.

He returned to Japan and with his colleagues at Toyota, focused on relentlessly

eliminating wasted time and activity in every part of the manufacturing process.
Costs and Production Lead times came down dramatically. They also developed a
breakthrough process for rapidly changing over equipment and production lines to
produce a variety of models on the same line. He also adapted what Toyoda,
Founder of the Toyota Group had invented in 1902, a power loom that stopped
anytime a thread broke and was re-started after fixing the problem thereby
preventing a recurrence.

This was the first example of Jidoka (Stop At An Abnormality), and he combined
this with other Key concepts such as Just-In-Time (JIT) and Heijunka (Level Loading)
to form the Toyota Production System … the foundation for Lean Manufacturing.

For more info: http://www.strategosinc.com/taiichi_ohno.htm

http://en.wikipedia.org/wiki/Taiichi_Ohno

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6
Technical Elements of TPS

 Kanban

 Just-in-time

 Small lot delivery

Flextronics Lean Enterprise
 Jidoka or quality in the process
～To make things in the right way～

 Heijunka or leveling of demand Just-In-Time Standard Takt Time

JIDOKA
To make Man (Autonomation)
Work Production
products at a
 Visual control time at good Stop at every
One Piece Flow
timing when
Standard WIP Production
Abnormality
it is sold Material
 5S or clean, orderly worksites Kanban Supermarket
System

Andon
Pull system
Machine Operational
Production
Availability

Leveled Production

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What is Jidoka ?

自動化（JIDOKA, means Automation）

You can find this word in Japanese dictionary

自働化（JIDOKA, meant Autonomation）

by TOYOTA, you cannot find this in Japanese dictionary

In Japanese,

動：Move 働：Work
What’s difference between 自動化JIDOKA and 自働化JIDOKA?

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自動化 (Automation)

- Old Concept

Just moving not working

Doesn’t respond to abnormalities

So keep producing defects

Bad
Bad Bad
Bad Good
Bad Good
Good Good
Bad Good
Good
Good Keep machine producing products
Good
without thinking

Moving system
=> TOYOTA defined such system as “自動機”

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自働化 (Jidoka)

- New Concept

Producing value added products

only Immediately respond to abnormalities
=> Working

Stop producing when any defect

is found
Bad
Good
Good Good
Good Good
Good Good Producing products with a sense
Good of judgment

Working system
=> TOYOTA defined such system as “自働機”

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Jidoka is Futuristic Quality System
Never pass defects to next operation

• Detecting abnormalities
• Responding immediately
• Eliminating causes

Jidoka is the Path to Zero Defect

Build in quality at each process

Feedback
Rework

A B C Ship
A B C Insp. Ship
Traditional Method Lean Method
Scrap
Build in quality at each process

What’s major disadvantage of traditional method?

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Why Jidoka ?

• Process capability - is indicated by amount of stoppage on Line

• Containment - Defects are quickly identified and contained in the zone
• Feedback - So that quick countermeasures can be taken
(Catching the culprit red-handed is always better than search for the culprit based on some clues
immediate correction)

“Jidoka is one of the factors

for the success of Lean
implementation” FLE
• High defect rates lead to frequent line
stoppages, which will make the flow JIT Jidoka
and pull difficult.
• Defects will jeopardize the takt time
and make the process uneven,
increasing lead time and cost. Heijunka

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Looms to Cars
Toyoda Family’s First Improvement

See at a glance - at a
See at a glance
distance - that one
- at a distance -
thread is broken.
that all threads
are OK Could easily make
this stop the loom
automatically
Session 1

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Jidoka Process

Jidoka drives a four step process that engages when abnormalities occur:

• Detect the abnormality

• Stop – bring attention to the problem
• Fix or correct the immediate condition
• Investigate the root cause and install a countermeasure

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Application of Jidoka

Detect
• Immediate stop
Can/should be • Fixed Stop
mechanized • Warn

Incorporate immediate response and correction.

• Respond
• Restore to run condition immediately
Must be designed
into the human
support system
Preventive Action
• Investigate root cause
• Install root cause countermeasure

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Application of Jidoka

JIDOKA - The ability for YOU to stop the process.

What does it mean to you ? & what do I do?

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Andon

How do you do that?

Trigger Andon

Every person has the RIGHT to stop the line.

“ Where you see an abnormality whether it be Safety/

Quality/ People Not Avbl on Line/ Material Shortage or Wrong/
maintenance issue/ anything that’s not normal “

WE WANT YOU TO STOP THE LINE

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Andon

Signal for action

SEE IT
HEAR IT
Visual – When signal can be seen by all
Audio – When people are not at seeing distance
Given that people are always on the move,
Audio-Video signal is an ideal option
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Andon

Guadalajara

Team at Work following Andon signal

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Jidoka

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Andon Cycle

Abmornality Defect
Detected
Occurrence
0 Cycle Time 60 secs
Andon Activated

Response/Decision Time Process

Stop
Call
Andon Activated Stops
Wait

Typical decision flow example

Is Individual
Escalate Determin Scale of Action
Empowered to NO Containment? NO
Appropriately Problem appropriately
Resolve

Yes
Yes

Can Resolve problem

Abnormality be
resolved within NO
Response
time

Record
Cancel Andon/
abnormality &
Resume PDCA
Corrective
production
Actions

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Andon

Safety Concern - USE ANDON

Disconnected safety device

ANDON “ON” ANDON “OFF”
YOUR COMMUNICATION TO OTHERS

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Andon

Incorrect Material /Kanban - USE ANDON

ANDON “ON” ANDON “OFF”

YOUR COMMUNICATION TO OTHERS

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Andon

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Application of Jidoka

A true human support system must be created as a part of any Jidoka

implementation.

• The resources necessary to respond, fix, and do root cause analysis must be in place
• Expectations of 5 W’s and 1 H need to be defined and adhered to
• Escalation mechanism (When/ How/ To Whom to escalate to be defined)
• Effectiveness of Andon system to be checked
• Leadership to convey that Andon will determine whether Operations can run or not
• Everyone on Line to have access to and be empowered to operate the Andon, when
really required

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Autonomation

Till now we’ve predominantly spoken about Stopping at an Abnormality

Let us now discuss about Auto-NO-mation …

Please note that Automation would have made the machine to “Move”

But Autonomation ensures the Machine will “Work”

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Example of Jidoka - Hanedashi

Safety
Barrier

Hanedashi

Shuttle
Parts

Hanedashi stands for Auto ejection, and we can design it

to “work” only if good part is produced
Note: Hanedashi is pre-requisite to Chaku-Chaku line

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Autonomation Example – Functional Tester

Before After

Manually open fixture after Functional Test Fixture opens automatically only if
Functional Test passes – else, needs to be
opened by Top Manager with password –
and corrective action taken

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Benefits of Autonomation

• Ensures & maintains safety

• Improved quality
• Empowers people – to try ideas (Every Idea is Important)
• Prevent defective items being delivered to next production phase
• Recognises abnormalities in automated production so adjustments/ repairs
can be made quickly
• Enables separation of machine and human work
• Eliminates the need for operators to continuously watch machines for defects
occurring
• Key driver for major gains in productivity

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 Zero Defect Approach – Link to Jidoka

• Jidoka – Stops Line and ensures only good parts move forward, thereby
controlling bonepile

• ZDL – proactively works on poka-yoking the error causing the defect …

identifies where and how to Poka Yoke

• If ZDL works effectively all the time, Jidoka (Andon & Autonomation) will
effectively not require to be activated … Jidoka is still needed because
this catches new defects coming up and provides feedback that can
ensure a Zero Defect Line

• Effectively, both Jidoka and ZDL together ensure that we

 Do not pass defect Jidoka
 Do not make defect ZDL Reduce Bonepile
 Do not accept defect ZDL/ Jidoka Ideal condition: Std WIP only
 Do not rework ZDL/ Jidoka

Note: Error is the CAUSE and Defect is the EFFECT, and so we need to Poka Yoke the error to prevent defects from happening

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Zero Defect Approach – Link to Jidoka

Quality is built into each process.

Jidoka: Send 100% defect free product to the next step.
Traditional Method Rework

Inspection
A B C A B C Ship

Scrap

Lean Method
Feedback is immediate

A B C Ship
Each process step
Is error proofed
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Source Inspection (1st Source Inspections)

Keeps Errors from becoming defects

 The only kind of inspection focused on complete elimination of defects.

 Catches errors and gives immediate feedback about them, before processing, so
the errors do not become defects.

 Asks.. what are the conditions necessary for success? And then builds in 100%
checks for those conditions. Can include real time online Statistical Process
Control.

 First Source Inspections are like Jidoka at the source of the error and will enable
Zero Defect Lines

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Poka Yoke

POKA - Inadvertent mistake

YOKE - to prevent

Pronounced (POH-kah YOH-kay)

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Poka Yoke

 A mistake-proof / fail-safe system or technique to help in achieving Defect free

production.

 Relies on simple reliable devices more than operators to perform Source,

successive check and self check inspections.

 Aims for reliable low cost implementation of 100% inspections.

 Best ideas typically come from the shop floor.

 For more literature and examples on Poka Yoke, please refer to training material on
Poka Yoke

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Poka Yoke

Used for:

visual control of quality to prevent defects from happening

Right position
Wrong processing Right processing position
position

Poka Yoke should be built into the process. It prevents making

defects, sending defects to the next process, and accepting the defect at the next process.

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 Poka Yoke for missing spring

Mechanical Poka Yoke

Missing spring Spring in housing

Poka Yoke to detect the spring

Sensor in the press machine to ensure having the spring in position prior to activating the
process. If the sensor does not detect the spring, the machine does not activate the cycle

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 Poka Yoke to avoid wrong mixed assembly
Mechanical Poka Yoke

4 color sensors

Assy mix validated by Avoid the operator criteria

Operator criteria
Poka Yoke to detect wrong mixed components
If one of the 4 Poka Yokes detects an error vs. the work order standard p/n; then the machine will stop and
the next operation (heat staking machine) won’t work. Heat staking Machine is controlled by PLC. The 4
Poka Yokes mentioned here are explained in the next slide.

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Pokayoke to avoid wrong mix assembly (cont)

If one of the 4 Poka Yoke

Correct bottom type detects an error then the
machine stops and the next Correct Housing
operation the heat staking
machine doesn’t work
Heat staking is controlled by PLC

Correct lens type Correct Cover color

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Poka Yoke for Audio Testing
Before After

The right sound must

be between 2400Hz
to 2500Hz

Sound Pressure (dB)

78

76

74

72
Sound Pressure (dB)

70

68

The right sound

66

must be between

1
45
89
133
177
221
265
309
353
397
441
485
529
573
617
661
705
749
793
837
881
925
969
1013
1057
1101
1145
1189
1233
1277
1321
1365
1409
1453
1497
1541
1585
1629
1673
1717
1761
1805
68dB to 77dB
Limits were defined with 800 samples at the line

Poka Yoke to ensure right audio levels

During the buzzer test, the operator had to decide if the beep level was correct or not. Was highly
subjective. There were lot of other noises around, making it more difficult for operator. The Poka Yoke
solution has a microphone that measures the Frequency and dB of the sound generated by Functional
Tester … and automatically gives a pass or fail result for the part, eliminating the human dependence.
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 Thank you

For further information, please visit :

http://intranet.flextronics.com/gbe/default.aspx

COMPANY CONFIDENTIAL Printed copies are uncontrolled copies.

Verify revision and approvals in the FMS Document Management System on ShareNet.