Jidoka
自働化·jidōka·"automation with human intelligence"
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Jidoka is automation with a human touch - building quality into the process by stopping immediately when a defect is detected.
Definition
Jidoka, often translated as "automation with a human touch" or "autonomation," is one of the two pillars of the Toyota Production System (alongside just-in-time). The concept involves building quality into the process by designing machines and processes to detect abnormalities and stop automatically when a defect occurs. This prevents defective products from moving downstream, makes problems immediately visible, and enables root cause analysis. The Japanese word uses the character 働 (work with human element) rather than 動 (simple motion), emphasizing intelligent automation that doesn't require constant human monitoring but stops for human judgment when needed.
Examples
A CNC machining cell was equipped with sensors that detected tool wear and dimensional drift. When measurements exceeded tolerance, the machine stopped automatically and activated an andon light. This jidoka implementation reduced scrap by 80% because defects were caught at the source rather than discovered at final inspection.
Key Points
- Jidoka separates human work from machine work, freeing workers from watching equipment
- The immediate stop when abnormalities occur prevents defect propagation
- Built-in detection at the source is more effective than downstream inspection
- Jidoka creates forcing functions for problem-solving and continuous improvement
Common Misconceptions
Jidoka eliminates the need for people. The purpose is not to eliminate workers but to elevate their role. Instead of monitoring machines, workers focus on problem-solving, improvement, and handling situations that require human judgment.
Jidoka is expensive high-tech automation. While sophisticated sensors help, jidoka often starts with simple devices—limit switches, fixtures that won't accept defective parts, or visual checks built into the process. The principle is more important than the technology level.