5 JidokaandQuality

Topics: Lean manufacturing, Production and manufacturing, Management, Quality assurance, Toyota Production System, ISO 9000 / Pages: 19 (1110 words) / Published: Dec 13th, 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

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