5 JidokaandQuality
WELCOME TO LPS SEMINAR
Outline of ＪＩＤＯＫＡ
(Built in Quality)
1
Basic Concept of LPS
Method
２ pillars of LPS
(1) Process Flow
J・I・T
LPS pre-condition
： Heijyunka
Lead time
Reduction
(reduce stagnation )
(2)
Takt time
Production
(3) pull production
JIDOKA
＊ Stop after completion (1) Separate man Work
& M/C Work
＊Stop at abnormality (2) Defect prevention
・ Small lot size
・1 piece flow production
→ Set UP time improvement
・ Machine layout by process flow
・ Simple flow
・Streamline of production
・Standardized work
・ KANBAN
・ Man-hour ⇒Manpower
・ Quality built in process
Standardized work
Pre-condition to support LPS （５Ｓ、 Observe company rule 、safety、 stable attendance ）
１、Awareness of Muda
３、GENCHI GENBUTSU
2、Cost varies depends on production method
４、Visual control
５. ５ times WHY analysis？
2
LPS JIDOKA Concept
▼ stop after completion mechanism ▼ stop at abnormality
・ visualized the abnormality
・ immediate take action
3
JIDOKA Aim
Stop any abnormal in process
NG
Always produce
100% good parts
Minimize
Man-power
4
What is JIDOKA?
(1)Abnormal
(2)Completed
Stop, alert
Never produce defect
Set the standard
Never operator to be observer
Able to apply quality built in process
Visualize abnormal
Able to separate manual and machine work
Able to produce good part
Solve problem
（visual control）
Able to run with minimum operator
Never produce defect ⇒ Cost reduce!!
5
Quality built in by JIDOKA complete, abnormal
stop
ON
STOP
1) Machine case
・stop upon complete
OFF
・alert the abnormal and stop
・prevent the abnormal (Poka Yoke)
2) Manual operation case
・KANBAN
・Andon
・Fix pitch stop system
6
Quality built in by JIDOKA sample
１）PokaYoke
3
2
1
Assembly jig
To ensure correct position for different child parts during assembly process
7
Quality built in by JIDOKA sample
2) Poka Yoke
Automated weighing scale machine to segregate OK & NG part by flipping mechanism
NG
OK
8
Quality built in by JIDOKA sample
3) Poka Yoke
Profile
Outline of ＪＩＤＯＫＡ
(Built in Quality)
1
Basic Concept of LPS
Method
２ pillars of LPS
(1) Process Flow
J・I・T
LPS pre-condition
： Heijyunka
Lead time
Reduction
(reduce stagnation )
(2)
Takt time
Production
(3) pull production
JIDOKA
＊ Stop after completion (1) Separate man Work
& M/C Work
＊Stop at abnormality (2) Defect prevention
・ Small lot size
・1 piece flow production
→ Set UP time improvement
・ Machine layout by process flow
・ Simple flow
・Streamline of production
・Standardized work
・ KANBAN
・ Man-hour ⇒Manpower
・ Quality built in process
Standardized work
Pre-condition to support LPS （５Ｓ、 Observe company rule 、safety、 stable attendance ）
１、Awareness of Muda
３、GENCHI GENBUTSU
2、Cost varies depends on production method
４、Visual control
５. ５ times WHY analysis？
2
LPS JIDOKA Concept
▼ stop after completion mechanism ▼ stop at abnormality
・ visualized the abnormality
・ immediate take action
3
JIDOKA Aim
Stop any abnormal in process
NG
Always produce
100% good parts
Minimize
Man-power
4
What is JIDOKA?
(1)Abnormal
(2)Completed
Stop, alert
Never produce defect
Set the standard
Never operator to be observer
Able to apply quality built in process
Visualize abnormal
Able to separate manual and machine work
Able to produce good part
Solve problem
（visual control）
Able to run with minimum operator
Never produce defect ⇒ Cost reduce!!
5
Quality built in by JIDOKA complete, abnormal
stop
ON
STOP
1) Machine case
・stop upon complete
OFF
・alert the abnormal and stop
・prevent the abnormal (Poka Yoke)
2) Manual operation case
・KANBAN
・Andon
・Fix pitch stop system
6
Quality built in by JIDOKA sample
１）PokaYoke
3
2
1
Assembly jig
To ensure correct position for different child parts during assembly process
7
Quality built in by JIDOKA sample
2) Poka Yoke
Automated weighing scale machine to segregate OK & NG part by flipping mechanism
NG
OK
8
Quality built in by JIDOKA sample
3) Poka Yoke
Profile