Autonomation (Jidoka) - Lean Six Sigma Glossary

Autonomation, also known as Jidoka, is a critical component of Lean Manufacturing, a management philosophy that emphasizes continuous improvement and waste reduction. Jidoka aims to create a system where machines and equipment automatically detect and stop defects, without the need for human intervention. This approach to manufacturing maximizes efficiency, reduces downtime, and eliminates the risk of human error.

What is Autonomation?

Autonomation is the integration of automation and human intelligence, resulting in a system where machines and equipment can work independently, without the need for constant supervision. The goal of Autonomation is to create a self-monitoring and self-correcting system that can identify and eliminate problems as they occur, rather than relying on human operators to detect and correct them.

The origins of Autonomation can be traced back to the early 20th century. Sakichi Toyoda, the founder of Toyota, developed the concept as a way to improve efficiency and quality of textile manufacturing operations. Toyoda’s approach was to create machines that were capable of detecting and stopping defects on their own, without the need for human operators to constantly monitor them.

The basic principle of Autonomation is to build in quality at the source. Which means that defects are detected and corrected as soon as they occur. This is achieved by equipping machines and equipment with sensors and other devices. Such devices can detect defects, and by programming them to automatically stop when a defect is detected. This allows operators to quickly identify and correct the problem. Rather than waiting for the defect to be discovered later in the process.

Implementing Autonomation

Implementing Autonomation requires a change in mindset. It’s not just about buying more equipment or adding more sensors. It’s about re-engineering the process and thinking about how to eliminate defects at the source. It also requires a strong commitment to continuous improvement, as you regularly need to identify and address the problems.

Implementing autonomation requires a systematic approach, including the following steps:

Define the Process

Identify the process to automate and define its scope and objectives.

Evaluate Equipment

Evaluate the equipment and machinery to determine their suitability for autonomation.

Design the System

Design a system that integrates automation and human intelligence, ensuring that the machines and equipment can work independently and detect and stop defects automatically.

Test and Validate

Test and validate the system to ensure that it is functioning as intended and that the quality of the product is not compromised.

Continuous Improvement

Continuously monitor and improve the system, identifying opportunities for further optimization and making adjustments as necessary.

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Benefits of Autonomation

One of the key benefits of Autonomation is that it helps to identify and eliminate problems early in the process. Before they can lead to larger issues down the line. This can result in significant cost savings, as well as improved quality and efficiency. By detecting and correcting problems as they occur, Autonomation can also help to reduce the need for rework. This further improve efficiency and productivity.

Another benefit of Autonomation is that it can help to improve safety. It reduces the need for operators to be in close proximity to potentially dangerous machinery. Additionally, it can help to improve the overall quality of products and services, as well as increase customer satisfaction.

The benefits of autonomation are numerous, some other includes:

Improved Quality

Autonomation enables machines to detect and stop defects automatically, reducing the risk of human error and improving the overall quality of the product.

Increased Efficiency

By eliminating the need for constant human supervision, autonomation allows machines to run continuously and reduces downtime, increasing overall efficiency.

Enhanced Safety

Autonomation reduces the risk of human injury, as workers no longer perform dangerous or repetitive tasks.

Better Use of Human Resources

With autonomation, workers are freed from monotonous tasks. This allows them to focus on more value-adding activities, such as problem-solving, decision-making, and continuous improvement.

Challenges of Autonomation

Implementing Autonomation can be a complex and challenging process. It requires a significant investment in equipment, sensors, and other technology. As well as a thorough understanding of the process and the specific requirements of the operation. It also requires a strong commitment to continuous improvement, and willingness to make changes to the process as necessary.

Some of the other challenges and limitations of Autonomation are as below.

High Initial Investment

Implementing autonomation can be expensive, as it requires the purchase and integration of new machines and technology.

Skilled Labor Shortage

There is a shortage of skilled labor in many industries, making it difficult to find the human workers needed to work with autonomation systems.

Integration and Maintenance Issues

Integrating and maintaining autonomation systems can be complex, requiring specialised expertise and resources.

Job Losses

While autonomation has the potential to increase efficiency and productivity, it can also result in job losses, as some tasks are automated and no longer performed by human workers.

A Few Examples

One example of Autonomation is the use of sensors on a production line. These sensors detect improperly aligned parts or incorrect amount of material usage. The machine will automatically stop and signal an alarm, alerting the operator to the problem. The operator can then make the necessary adjustments and restart the machine, without having to wait for discovery of the defective part later in the process.

Another example of Autonomation is the use of a robotic arm in a packaging line. This arm automatically detects an incorrect seal of a package and stops the line, alerting the operator to the problem. The operator can then make the necessary adjustments and restart the line, without having to wait for discovery of the defective package later in the process.

Some other applications are;

Assembly Line Production

Autonomation is widely used in assembly line production, where machines and human workers work together to assemble components and products.

Custom Product Manufacturing

Autonomation is especially useful in the manufacturing of custom products, where human workers can quickly adapt to changing requirements and make adjustments as needed.

Quality Control

Human workers can use autonomation to perform quality control checks on products and components, ensuring that only high-quality products are produced.

Packaging and Shipping

Autonomation can be used to automate repetitive tasks such as packaging and shipping, freeing up human workers to focus on more complex tasks.

Final Thoughts

Autonomation is a critical component of Lean Manufacturing, enabling machines and equipment to work independently, detect and stop defects automatically, and improve overall efficiency, quality, and safety. By freeing workers from monotonous tasks, autonomation also enables them to focus on more value-adding activities and drive continuous improvement. By implementing a systematic approach to autonomation, organizations can reap the benefits of this approach to manufacturing and achieve their production goals.

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Sachin Naik

Passionate about improving processes and systems | Lean Six Sigma practitioner, trainer and coach for 14+ years consulting giant corporations and fortune 500 companies on Operational Excellence | Start-up enthusiast | Change Management and Design Thinking student | Love to ride and drive