5 JidokaandQuality

Topics: Lean manufacturing, Production and manufacturing, Management Pages: 19 (1110 words) Published: December 13, 2014
WELCOME TO LPS SEMINAR

Outline of JIDOKA
(Built in Quality)

1

Basic Concept of LPS
Method

2 pillars of LPS

(1) Process Flow

J・I・T
LPS pre-condition
: Heijyunka

Lead time
Reduction
(reduce
stagnation )

(2)

Takt time
Production

(3) pull production

JIDOKA

* Stop after
completion

(1) Separate man Work
& M/C Work

*Stop at
abnormality

(2) Defect prevention

・ Small lot size
・1 piece flow production
→ Set UP time improvement
・ Machine layout by process flow
・ Simple flow
・Streamline of production
・Standardized work

・ KANBAN

・ Man-hour ⇒Manpower
・ Quality built in process
Standardized work

Pre-condition to support LPS (5S、 Observe company rule 、safety、 stable attendance )

1、Awareness of Muda
3、GENCHI GENBUTSU

2、Cost varies depends on production method
4、Visual control
5. 5 times WHY analysis?

2

LPS JIDOKA Concept
▼ stop after completion
mechanism

▼ stop at abnormality

・ visualized the abnormality
・ immediate take action
3

JIDOKA Aim

Stop any abnormal
in process
NG

Always produce
100% good parts

Minimize
Man-power
4

What is JIDOKA?
(1)Abnormal

(2)Completed
Stop, alert

Never produce defect

Set the standard

Never operator to be observer

Able to apply quality
built in process

Visualize abnormal

Able to separate manual
and machine work

Able to produce good part

Solve problem

(visual control)

Able to run with
minimum operator

Never produce defect ⇒ Cost reduce!!

5

Quality built in by JIDOKA
complete, abnormal

stop

ON

STOP

1) Machine case
・stop upon complete
OFF
・alert the abnormal and stop
・prevent the abnormal (Poka Yoke)
2) Manual operation case
・KANBAN
・Andon
・Fix pitch stop system
6

Quality built in by JIDOKA sample
1)PokaYoke
3
2

1

Assembly jig

To ensure correct position
for different child parts
during assembly process
7

Quality built in by JIDOKA sample
2) Poka Yoke
Automated weighing
scale machine to
segregate OK & NG part
by flipping mechanism

NG

OK

8

Quality built in by JIDOKA sample
3) Poka Yoke

Profile jig

To ensure correct part for
the next process and
prevent mix-up part

9

Quality built in by JIDOKA sample
4) Poka Yoke

10

ANDON system


mechanism to alert or stop in any abnormal
situation of machine or operator
call
STOP

11

Fix pitch stop system
Apply for manual operation concept “stop in abnormal situation”

Fix pitch stop

1 body pitch




End point

Start point

Part storage

Process element

(1) Fix pitch range, assy by standardized work
(2) Part & tool storage suit and fit with process spot
(3) Unable to complete by fix pitch cycle, call for relief
(4) If relief does not succeed work in a pitch,
A line stops by a fixed position stop line automatically.

12

Is your shop floor make it possible to tell
the truth?

Don’t Get Angry

The shop floor atmosphere
① Honest report →

② Scold the PIC

③ It’s suffering

④ Hiding the fact then give
wrong report



⑤ Cannot identify the real cause

⑥ Not intentionally
⑦ Defect happened due to lack of skill and misunderstanding ⑧ To worsen the condition by scolding and anger
⑨ Don’t be angry ,work together to prevent the reoccurrences ⑩ It is permitted if prevention of reoccurrence is taken
then it will become a better shop floor.

Quality is..
Customer
satisfaction
Product
Quality

Design Quality
(Aim quality)

Quality of
Work

Customer
Quality

Production
Quality
(actual)

Service Quality
(Price, delivery service)

IF DON’T DO JIDOKA

OK

Defects flow out
OK

Defects accumulated
Delay in delivery

Quality Built-In
…Required idea… own process completion activity

Human :
make mistake

Equipment :
breakdown

Investigate the important conditions in operation
in order to produce good quality parts
1. Design requirement...
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