IENG 451 / 452 Jidoka: Reliability, Quality, Poke Yoke IENG 451 - Lecture 23 Jidoka: Reliability, Quality, Poke Yoke 5/19/2018 IENG 451 Operational Strategies (c) 2016 D.H. Jensen

House of Lean CUSTOMER FOCUS JUST IN TIME INVOLVEMENT JIDOKA Hoshin Planning, Takt, Heijunka Involvement, Lean Design, A3 Thinking JUST IN TIME INVOLVEMENT JIDOKA Standardized Work 5S TPM Kaizen Teams Suggestions Safety Activities Hoshin Planning Flow Heijunka Takt Time Pull System Kanban Visual Order (5S) Robust Process Involvement Poke Yoke Zone Control Visual Order (5S) Problem Solving Abnormality Control Separate Human & Machine Work Involvement STANDARDIZATION Standardized Work Kanban, A3 Thinking Visual Order (5S) Hoshin Planning STABILITY Standardized Work, 5S, TPM Jidoka, Heijunka, Kanban 5/19/2018 IENG 451 Operational Strategies

Jidoka Concept – Sakichi Toyoda Jidoka has been defined as “automation with a human mind” Humans make mistakes Since humans work in the system, you can never eliminate mistakes Machines make defects Since machines are supervised by humans, use the humans to find and fix the machines that make defects “… thus Zero defects is absolutely possible.” – Shigeo Shingo 5/19/2018 IENG 451 Operational Strategies

IENG 451 Operational Strategies Jidoka Human Error Rates: Dennis (2015) p. 126 5/19/2018 IENG 451 Operational Strategies

IENG 451 Operational Strategies Jidoka Concept Really, we are leveraging on Process Capability: Old World Mfg – produce as much and as fast as possible. Replace defective products when someone complains. New World Mfg – NEVER pass on a defective product. Stop the line and fix the process … and continually improve the process By continually strengthening Jidoka, we are improving our process capability, and putting our firm in a better position for the future. Focus on improving process capability (Poke Yoke) – by investigating defect causes and fixing the machines that cause them and by eliminating human mistakes Focus on containing defects (Zone Control)– by having people find defects and containing them within the zone of control 5/19/2018 IENG 451 Operational Strategies

IENG 451 Operational Strategies Poke Yoke Most Common Errors: Missing Process Steps Process Errors (does not meet standard) Mis-set Work Pieces (piece set backwards) Missing Parts Wrong Parts Faulty Machine Operation Adjustment Error (depth of cut stop set wrong by operator) Equipment Set Up Wrong Tools / Fixtures / Jigs Inadequately Prepared A Good Poke Yoke either prevents these or makes an error obvious: Simple, with a long life Highly reliable Low cost Designed for workplace conditions 5/19/2018 IENG 451 Operational Strategies

IENG 451 Operational Strategies Poke Yoke Examples A Good Poke Yoke either prevents errors or makes an error obvious: Humans are not good at simple, repetitive motions (like sorting clips) Machines can do the same action repeat ably 5/19/2018 IENG 451 Operational Strategies

IENG 451 Operational Strategies Poke Yoke Examples A Good Poke Yoke either prevents errors or makes an error obvious: Humans are not good at dull tasks (like orienting rivets) Simple additions to machines can do the task 100% of the time. 5/19/2018 IENG 451 Operational Strategies

IENG 451 Operational Strategies Poke Yoke Examples A Good Poke Yoke either prevents errors or makes an error obvious: In the temporary case, a human could orient the bottle caps. But to do it long term, would be a waste of the human capacity to solve problems. A three stage, simple addition to the machine can do the task 100% of the time at a lower cost. 5/19/2018 IENG 451 Operational Strategies

Jidoka Implementation Involvement is Everything: people love to solve problems. SMART Goals: Simple Measurable Achievable Reasonable (relevant) Trackable Motivation: Extrinsic Motivation – comes from physical rewards Monetary Gifts Intrinsic Motivation – comes from personal satisfaction Recognition by peers Personal growth (skills development) & self-actualization (self-accomplishment) Contribution to a broader / larger goal 5/19/2018 IENG 451 Operational Strategies

IENG 451 Operational Strategies Questions & Issues 5/19/2018 IENG 451 Operational Strategies (c) 2016 D.H. Jensen