Jidoka (Autonomation): Automation with a Human Touch

Building on last week’s post about Poka-Yoke (Error-proofing) – designing systems, devices, or processes in a way that makes it impossible (or very difficult) to make a mistake – let’s dive into another powerful Lean tool: Jidoka, or “autonomation.” This concept from Toyota blends automation with human intervention to ensure quality and prevent defects before they escalate.

Note: Autonomation is a form of automation where technology performs tasks with minimal human involvement but ensures human intervention when issues arise. This approach is more cost-effective than fully automated systems that require self-diagnosis and correction.

What is Jidoka?

Jidoka combines automation with the insight of human workers to catch defects as they occur, preventing them from propagating through the production process. The idea is to stop production immediately when an issue is detected and then investigate the root cause, ensuring continuous quality improvement.

There are more ways than you might think to apply this concept in your systems. Think about how they could catch and resolve issues early—sometimes, it’s just about knowing their capabilities. Just picture this: In maintenance, if parts aren’t in stock, the maintenance information system may prevent scheduling tasks and trigger an order. If this functionality isn’t active, it’s likely just a matter of turning it on. Of course, whether to implement it depends on your objectives; in some organizations, the preference might be to allow scheduling with a warning instead.

At its core, Jidoka relies on two key elements: Autonomation (intelligent automation) and Human Intervention. Let’s explore both in more detail.

1. Autonomation (Intelligent Automation)

The first part of Jidoka involves intelligent automation systems that can stop processes when a defect or anomaly is detected. This allows defects to be addressed before they can cause further issues or lead to waste (non-value-added activities).

In an airline context, imagine a Central Reservation System that can prevent access to customer data if a cybersecurity threat is identified. When the system detects abnormal activity, it halts data access and alerts the IT team to investigate and resolve the issue.

Similarly, Crew Management Software can prevent the assignment of crew members to flights if there’s a scheduling conflict or availability issue. This ensures that problems are caught early and resolved before impacting operations.

2. Human Intervention

While Autonomation can detect and stop issues, human intervention is essential to investigating and resolving problems. When a defect is detected and a process halts, human workers are responsible for determining the cause and taking corrective actions.

For instance, when a machine stops due to an issue, an operator investigates the cause, whether it’s a malfunction or human error. The problem is addressed, and steps are taken to prevent recurrence.

In airline operations, a Flight Planning and Navigation System might stop creating a flight plan if there’s a conflict with airspace restrictions. Human planners would then adjust the plan and resolve the issue, ensuring the flight can proceed without delays or safety concerns.

The Benefits of Jidoka

Implementing Jidoka offers several key benefits:

• Prevents Defects Early: By stopping processes when an issue is detected, Jidoka prevents defects from spreading and reduces waste.

• Minimizes Downtime: Early detection allows for quicker resolution, reducing downtime and improving operational efficiency.

• Enhances Safety: In aviation, safety is paramount. Jidoka helps ensure that potential safety issues are addressed before they can cause harm.

• Fosters Continuous Improvement: Jidoka empowers workers to solve problems and contribute to ongoing process improvements, which is central to Lean principles.

Conclusion

Jidoka blends automation with human judgment to create a proactive approach to quality control. For airlines, implementing Jidoka systems and processes can lead to better quality, increased efficiency, and improved safety. By detecting issues early and empowering employees to resolve them, Jidoka helps prevent defects from spreading, ensuring smoother operations and continuous improvement.

Want to know more about the specific steps to develop and implement Poka-Yoke and Jidoka in your systems and processes?
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