Duration
2 days
Introduction
Industrial revolution age sees the introduction of automatic operation via the application of machines. These automation improve the speed of production and reduce man power application, thereby reduce the cost of manufacturing.
However, these automated processes/machines still produce defectives which need rework or scrap.
Defective products, machine stoppages, errors etc. need human interference. In Toyota Production System (TPS), Jidoka (Automation with Human Touch) was introduced to eliminate or reduce defective products by appropriate human interference. Jidoka need human empowerment or decision to stop the production instead of letting the machine continuously producing defective products. Human involvement in the form of Autonomous Maintenance is very effective form of support for Autonomation Implementation.
Application of Poka Yoke devices (sensors, gauges, gadgets) were introduced to prevent or stop errors from processes
or machines as well.
Moving forward to Industry Revolution 4.0, Jidoka will be further enhanced by the use of sensors or Artificial Intelligence (AI) to make production processes even more efficient and effective.
Application of Jidoka is in alignment with today’s industry revolution 4.0 where the future direction is the development of intelligent and self diagnosed machines.
In this session, the methods and examples of Jidoka will be explained and illustrated with real life cases.
Objectives
After attending this session, participants are able to:
- 1. Apply proactive method to detect quality defect in early stage.
- 2. Develop the culture of “Do it right at First Time and Every Time”
- 3. Understand machine/product abnormality
- 4. Practice Toyota Production System (TPS) principles.
- 5. Enhance machines or processes using Jidoka.
- 6. Set up Defect Free operation.
Methodology
This session will be conducted in workshop manner. Examples from the participant lines will be used as case studies
and applied as an working examples. Apart from the workshop, the course also will have lectures and group study.
Sample of “Jidoka” projects will be shown during the training.
Contents
- 1. Introduction to Toyota Production System (TPS).
- Goals – Wastes Elimination, types of production wastes.
- Concepts and Principles of TPS
- Tools to achieve TPS.
- Cultural evolution needed.
Exercise : Develop Gap Analysis for your company compared to TPS requirements.
- 2. Jidoka- Automation with Human Touch.
- Definition of Jidoka in TPS.
- Involvement of Machines in Production Activity during automation.
- Human involvement in Machine assistance to reduce or eliminate defectives, faults, machine stoppages etc.
*AM (Autonomous Maintenance) Implementation
* 7 Steps of Implementation
* AM team formation and preparation
* Step by steps implementation.
* Practical and Line Activities.
- Application of Poka Yoke devices or processes to support Jidoka
- Exercise : Based on your selected product, develop product failure modes versus machine modules.
- 3. Jidoka in Industry Revolution 4.0,
- Application of Artificial Intelligence and Sensors to prevent Product defects.
- Self diagnosed machines structure.
- Human independent/Autonomous working machines.
- Examples of Self diagnosed, self managed machines
Exercise : Select one process or machine, develop list of additional enhancement to achieve Jidoka Operation.
- 4. Case studies and tips for implementation.
Who Should Attend
All Equipment, Quality and Production Personnel (Line Leaders, Operators, Supervisors), Executives, Engineers and Managers should find this course useful in developing a defective free production environment through the use of Jidoka environment. It is a quantum leap and mindset breakthrough from current production environment.
Programme scope, delivery arrangements and suitability are confirmed during enquiry.