Every business strives for continuous workflow, which leads to overall efficiency. Jidoka is the mainstream lean tool that maintains the workflow by detecting and eliminating the problems in the lean supply chain.
If your goal is to deliver according to your customer’s expectations and maintain a steady workflow in a process that can quickly identify and rectify issues; that too without keeping much inventory, stick with us, this comprehensive guide on Jidoka covers the concept from A to Z.
Here’s what we’ll cover in this guide:
Table of Contents
What is Jidoka in Lean? — Understanding the Basics
How to Implement Jidoka 3 steps
Step 1: Recognizing the importance of Jidoka
Step 3: Start with Small Projects
Examples of Jidoka in Everyday Situation
Poka-Yoke & Jidoka! Same or Different?
After just a little time, Jidoka was revered as one of the two pillars that strengthened the Toyota Production System. These two pillars have transformed Toyota into the manufacturing giant icon we know today. But as a matter of fact, Jidoka is little known within the lean manufacturing toolset and almost forgotten to some point with less attention than JIT.
Also known as autonomation, which means automation with human intelligence and slight intervention, Jidoka is a lean manufacturing concept focusing on defect-free products by enabling machines to detect faults early on.
What is Jidoka in Lean? — Understanding the Basics
Jidoka is a simple yet impactful lean manufacturing tool. It centers around the core philosophy of delivering error-free or low-quality products to your customers. This technique enables the production process machines to distinguish the good from the bad part autonomously, surprisingly, without any operator.
In simpler words, Jidoka is a lean concept that drives continuous workflow by creating processes that create autonomous processes with built-in quality control.
Think of a whole batch failing the quality control tests! Sounds horrible? Now flip the situation and imagine a batch that stops the entire processing line, and initiates a troubleshooting or rectification process, because of an error detected right at the start —thanks to Jidoka for making it possible.
In lean manufacturing, Jidoka is implemented with the help of sensors. These sensors instantly detect if a product doesn’t meet the set criteria, trigger the machine to shut itself, or initiate an alert response.
Origin of Jidoka
The impactful Jidoka came into existence in 1869. Credit goes to the Japanese inventor Sachiki Toyoda, who later founded the Toyota Group. The story started after his machine created a stir across the industry at the time. He developed a loom system that would automatically stop once the thread broke. This device could stop the shuttle of the automatic loom by immediately sending a signal highlighting a problem. This innovative design caught global attention. A UK company purchased the patent, and the funds from this sale helped establish the Toyota Group.
Toyoda’s invention showcased the essence of Jidoka by pausing production to fix problems immediately, a key principle in quality manufacturing.
Purpose of Jidoka
This Lean manufacturing tool centers around quality control at every step of the production process. It stresses the immediate stoppage of the whole production line when an error is detected. This stoppage might seem painful initially, but it avoids producing substandard or defective products while promoting the production of high-quality products, subsiding any such inconvenience.
Key Benefits of Jidoka
That, however, is one of many benefits! Here are some other ways Jidoka can supercharge the improvement of your business:
- It reduces the potential negative impact on sales
- Drives operational excellence
- Saves you from inadequate customer response
- Make products that meet and exceed customer expectations
- Early detection of error minimizes the long-term effects of a defective batch
- Spots the problem behind the faulty products and addresses it
- Take measures to stop the same problem from recurring
- Fosters a culture of continuous improvement
4 Basic Elements of Jidoka
Jidoka relies on four essential elements that are still relevant and applicable. The application of these elements ensures continuous improvement in your production process.
1. Detect Abnormalities
The first step is identifying abnormalities, such as poor-quality raw materials or defective products. Machines are designed to react automatically through sensors, cameras or measurement devices to these failures and send alerts to notify employees about the issue.
This is the most important step, as it prevents the problem from spreading further and lays the foundation for resolving it.
2. Stop Production
Once an issue is detected, the system halts production immediately, often without human intervention. However, in emergencies, workers must also be able to stop the production line manually to prevent further damage.
3. Take Corrective Actions
After production is stopped, corrective measures are taken to resolve the issue. Once the problem is fixed, production resumes smoothly.
This step minimizes disruption and ensures the issue is addressed correctly before operations continue.
4. Prevent Recurrence
In this final step, efforts are made to prevent the problem from happening again. Teams investigate the root cause, plan solutions, and implement strategies to avoid future disruptions. Very similar to the PDCA cycle.
This proactive approach ensures long-term improvements and reduces the chances of recurring issues.
How to Implement Jidoka 3 steps
The 3-step implementation of Jidoka requires a tremendous shift in mindset. Here’s how you can do it:
Step 1: Recognizing the importance of Jidoka
The first step starts at the management level. Leaders must view Jidoka as a long-term strategy for growth rather than a production halt or new buzzword. By recognizing its value, management can foster a culture where the organization appreciates and practices Jidoka.
Step 2: Conduct Assessment
This step requires a thorough assessment of the entire process before you initiate it. It’s advised to take some time to study and identify the requirements for a smooth production process beforehand.
Assessment can be carried out by:
- Evaluating the current processes
- Identifying resources and workforce skills
- Assessing readiness
- Developing strategies
Step 3: Start with Small Projects
If you’re implementing Jidoka for the first time or just the start, the best practice is to begin with pilot project testing. Try Jidoka on a selected machine or pilot production line before taking it to the organizational level. This will help you understand the process’s ups and downs and details until you master it.
By following these steps, you can successfully implement Jidoka and achieve sustainable improvements in your business.
Examples of Jidoka in Everyday Situation
This section of our blog is going to be the most exciting one! Here, we’ll reveal the most common instances you have encountered.
Electronic Devices
Have you seen a printer instantly shutting down when it detects a paper jam? As soon as it happens, the printer immediately issues a visual or audible signal to alert the user to intervene and solve the issue.
Healthcare
Another common example of Jidoka is the healthcare sector, where providers monitor patients’ vital signs with specialized devices or equipment. When these devices detect any abnormality in the vitals, they alert medical staff through signals, asking them to take instant action.
Poka-Yoke & Jidoka! Same or Different?
Both these lean tools, developed by Toyota Group, are often confused for being the same. Although they are similar in many ways, they are still quite different.
Wondering how? Walk through the given points to learn how.
| Poka-Yoke (Mistake-Proofing) | Jidoka (Autonomation) |
| Aims to eliminate errors by implementing preventive measures
Stresses upon repetitive tasks where human mistakes are more likely to happen. Uses mechanisms or designs that anticipate and prevent errors before they happen. Example: Dishwashers that won’t start until the doors are securely closed. |
Relies on machines or systems laced with monitoring elements like sensors and detectors.
It focuses on stopping production to prevent defective products and demands immediate solutions. Combines autonomy (decision-making) with automation. Example: Printers that immediately stop on paper jam. |
To put it simply, Jidoka responds to errors by stopping operations and addressing issues as they arise, and the result is Improved quality! On the other hand, Poka-Yoke prevents errors from occurring by designing systems that make mistakes impossible or unlikely.
Conclusion
Hopefully, what Jidoka is in Lean is no longer a query! To summarize the whole concept, it’s a lean manufacturing tool that strives to detect problems immediately in any reduction process. The most thrilling part of Jidoka is automation with intelligence. The machine is the mainstream hero that automatically shuts down when it senses a problem in the production process.
If you, as a business, aim for continuous workflow, defect-free products, and qualitative results, implement Jidoka today to witness the impactful results.
