What is Jidoka?
Jidoka (自働化) is often translated as “automation with a human touch” or “autonomation”. Machines and processes are designed to detect abnormalities and stop automatically, and people are empowered to stop the line (the famous Andon cord) when they see a problem.
The 4 steps of Jidoka
- Detect the abnormality.
- Stop the process.
- Fix the immediate problem.
- Investigate the root cause and put a countermeasure in place.
Jidoka beyond the factory
A billing system that halts an invoice run when totals don't match the order book; a freezer that alerts and locks dispatch when the temperature goes out of range; a checklist that won't let a shift close until cash is reconciled.
Common mistakes to avoid
- Stopping without fixing the root cause — the same stop happens again.
- Punishing people who raise problems, so they stop raising them.
- Too many false alarms, so alerts are ignored.
How DOOfy helps
Jidoka needs fast detection. DOOfy watches operations and building data for abnormalities — out-of-range readings, mismatched numbers, unusual patterns — and alerts the right person, so problems are caught where they start.
Frequently asked questions
What is the difference between Jidoka and automation?
Plain automation keeps running even when something is wrong. Jidoka adds the ability to detect problems and stop, so defects aren't mass-produced.
What is an Andon cord?
A signal — originally a cord on the assembly line — that any worker can pull to stop production and call for help when they see a problem.