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

2. 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

3. 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

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

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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

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