The Lean tool Jidoka involves the transfer of human intelligence to automated machinery. Consequently, machines can detect the production of a defective part and immediately stop themselves while requesting help. Sakichi Toyoda pioneered this idea at the turn of the twentieth century. He invented automatic looms that stopped instantaneously when any thread broke. Therefore, a single operator is enabled to oversee many machines with no risk of producing vast amounts of defective cloth.
How does Jidoka work?
The table below demonstrates the guidelines for implementing Jidoka. It elaborates on the areas where machines must be designed as a part of the human support system.
Table 1 – Guidelines to implement Jidoka
The chart below shows how in Jidoka, a machine stops once an abnormality occurs. Either the machine itself or the supervisory staff should take corrective action immediately. Furthermore, the supervisor should examine the root cause and carry out countermeasures to prevent the problem from occurring in the future.
Figure 1 – The root cause of the abnormality must be investigated and prevented