1. Ninbennoaru Jidoka
Mind of a human to troubleshoot
and correct failures
Anand Subramaniam

2. “Everyone is a genius at least once a year; a
real genius has his original ideas closer
together.”
- Georg Lichtenberg
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3. Toyota Production System (TPS)
TPS
Single Piece
Flow Poka Yoke
Jidoka
People
JIT
Pull Involve-
ment Andons
Takt Time
Heijunka
Sequencing Leveling
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4. Jidoka
Automation with a human touch = Autonomation
Origin of Jidoka - Type G
Toyoda Automatic Loom
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5. What is Jidoka ?
 The Japanese word for “autonomation”
 Toyota Motor defines the word as, “investing machines with human
intelligence.”
 Can be used with machines or people
 One of the two main pillars of TPS (Toyota Production Systems)
 Machines are designed to stop automatically when a problem is
detected or any operator on the line, has the power to stop
production
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6. Why use Jidoka ?
 Lower costs
 Increase quality
 Reduce lead time
 Improve customer service
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7. Ninbennoaru Jidoka
 Alerts the worker, when a defective item is
produced or a machine malfunction has
occurred
 This allows the problem to be dealt with immediately,
preventing the production and passing of defects
 Problems and the defects they cause, can be more
quickly localised, isolated, and corrected
 . 7

8. Prevention Techniques
 Poka Yoke
 Visual control of quality
 Prevents defects from happening
 Andons
 Light to signal production line status / attention
• Red: line stopped
• Yellow: call for help
• Green: all normal
 Pin-Pan-Pon
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9. Jidoka Process
Poka Yoke Devices
Investigate the
Fix or correct
Detect the root cause and
Stop the immediate
abnormality install counter-
condition measures
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10. “Try to learn something about everything
and everything about something.”
- Thomas Henry Huxley
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11. Good Luck
http://www.linkedin.com/in/anandsubramaniam
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