Topics
3P - Production Preparation5S - Workplace Organization
Activity Based Costing
Agile Manufacturing
Autonomation
Benchmarking
Best Practices
Business Intelligence
Competitive Intelligence
Continuous Flow
Continuous Improvement
Design for Manufacturing
Ergonomics
Heijunka
Hoshin Kanri
Jidoka
Just in Time
Kaizen
Kanban
Knowledge Management
Lean Accounting
Lean Six Sigma
Lean Supply Chain
Mistake Proofing
One Piece Flow
Poka Yoke
Policy & Strategy Deployment
Pull Manufacturing
Quick Changeover / SMED
Quick Response Manufacturing
Safety & Health
Six Sigma
Standard Work
Statistical Process Control
Strategic Planning
Supply Chains
Takt Time
Teams
Theory of Constraints
Total Productive Maintenance
Training Within Industry
Value Streams
Visual Factory
Work Cells
Lean Enterprises
Lean ConstructionLean Education
Lean Government
Lean Healthcare
Lean Job Shops
Lean Manufacturing
Lean Office
Lean Product Development
Lean Software & IT
Autonomation and Jidoka
Autonomation describes a feature of machine design to effect the principle of "Jidoka" used in the Toyota Production System. Autonomation, or Jidoka, may also be described as "intelligent automation'" or "automation with a human touch."
Autonomation transfers a level of human intelligence to automated machinery. Machines thus detect even a single defective part and immediately stop while asking for help. The concept was pioneered by Sakichi Toyoda at the turn of the twentieth century. He invented automatic looms that stopped instantly when any thread broke. This permitted one operator to oversee many machines without risk of producing large amounts of defective cloth. Taiichi Ohno considered Jidoka (Autonomation is one variant) as one of the two pillars of the Toyota Production System. See also jidoka. The purpose of autonomation is the rapid or immediate address, identification and correction of mistakes that occur in a process. For instance rather than waiting until the end of a production line to inspect a finished product, autonomation may be imployed at early steps in the process to reduce the amount of work that is added to a defective product. A worker who is self-inspecting their own work, or source-inspecting the work produced immediately before their work station is encouraged to stop the line when a defect is found. This detection is the first step in Jidoka. A machine performing the same defect detection process is engaged in autonomation. |
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Once the line is stopped a supervisor or person designated to help correct problems give immediate attention to the problem the worker or machine has discovered. To complete Jidoka, not only is the defect corrected in the product where discovered, but the process is evaluated and changed to remove the possibility of making the same mistake again. This "mistake-proofing" of the production line is called Poka Yoke.
Taiichi Ohno and Sakichi Toyoda, originators of Lean philosophy and practices in the manufacturing of textiles, machinery and automobiles considered Poka Yoke & Jidoka (mistake-proofing and autonomation) the pillars upon which Lean is built.
PowerPoint Presentations
Lean Overview - 3P - 5S - Jidoka - Kaizen - Value Streams - Visual Factory - Pull - JIT - Kanban - Quick Changeover - Cellular Manufacturing - Theory of Constraints - TWI - TPM - Lean Office - TQM - SPC - Root Cause Analysis - Six Sigma - FMEA - Balanced Scorecard - Competitive Intelligence - Knowledge Management - Job Design - Outsourcing Strategy - Supply Chain Strategy - Strategic Management - Project Management - and many more
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Training Packages
Lean Overview - Value Stream Mapping, 5S, Quick Changeover, Lean Manufacturing Workshop, 5S Office, VSM Office, Classic Kaizen, Quick and Easy Kaizen, Lean Overview (Spanish), 5S (Spanish), Value Stream Mapping (Spanish)
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DVD Videos
Life in a Workcell - Batchin' - What Lean Means - Kaizen Blitz - Shigeo Shingo - Lean Accounting - ESD - 5S - Quick and Easy Kaizen - Customer Satisfaction - Work Teams - Velocity at Dell - Strategic Planning
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Games and Simulations
Lean Manufacturing - Just in Time, Factory Flow - 5S
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Factory Toolbox
Lean Toolkit - Procedures Toolkit - Quality Toolkit - Tools and Forms Toolkit - Engineering Toolkit - Materials Toolkit - Safety Toolkit - HR Toolkit - Six Sigma Toolkit - Finance Tookit
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Online Learning
Lean Overview - 3P - 5S - Jidoka - Kaizen - Value Streams - Visual Factory - Pull - JIT - Kanban - Quick Changeover - Cellular Manufacturing - Theory of Constraints - TWI - TPM
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The Gold Mine: A Novel of Lean Turnaround