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Jidoka, an automatic production error detection system

the Jidoka was invented by the Japanese Sakichi Toyoda, the founder of Toyota. Thus Jidoka means in French autonomation, transfer from man to machine. The objective is to set up automatic non-conformity detection systems so that the machine that produces stops. Over time, this method is increasingly used to reduce the number of operators required to monitor the machine.

Improved Lean Manufacturing with Jidoka

The relative intelligence called Jidoka, is one of the pillars of TPS, Toyota Production System but also a pillar of Lean Production, or more commonly known as Lean Manufacturing, just like just-in-time. If this method is used so much, it is notably for its operation. In order to avoid the creation of defective products, the Jidoka allows problems to be solved as soon as they occur in the production process. This solution makes it possible to be more productive, to reduce the time of change of series, to eliminate the 7 types of waste. The 6 Sigma method is a defect removal approach and takes up the main concepts of the Jidoka.

Quality anomaly management in the Lean Manufacturing chain

Take a factory that manufactures 3 types of products in different volumes, quantities. Here is the representation of the 3 products, one for a different color. Now imagine the average monthly number of orders for each product line.

The TPM method aims for zero defect. This is the first step in launching continuous improvement or progress initiatives for industrial groups. In particular because Total productive Maintenance allows the optimization of machine productivity. This method, developed by the Toyota Production System, makes it possible to eliminate the non-quality of the machine. It is not the only tool to eliminate problems of non-quality.

The Poka-Yoke, meaning coded, is a device put in place to reduce errors, unintended problems. The mounting, assembly or connection parts are the main ones affected by these errors. This help is amplified by the 5S method, whose goal is to work in an organized work area, arranged to improve the performance of the workstation and the quality of production.

The sooner a problem is detected, the sooner it can be solved and the more operational the production line will be. In order to detect and eliminate anomalies, defects and quality problems as quickly as possible, production lines can install an Andon system. The Andon system is a modular light or sound column that signals the status and status of a machine, plant or process. To solve these anomalies quickly the QRQC approach is interesting to know and exploit.

Essential tools to implement the Jidoka method

Discover SESA SYSTEMS creations to serve the process and prolong production efficiency.

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