[Toyota Production System] Jidoka: Stopping Production, a Call Button and an Andon Electric Board

Summary

The video script describes an innovative production system where workers can press a call button to signal irregularities. A yellow lamp on a board alerts the leader, who rushes to resolve the issue with a music-like siren. If unresolved, the line stops, and the lamp turns red. Once fixed, the leader releases the button, restarting the line. This ensures production moves forward without defects, emphasizing quality and efficiency.

Takeaways

• 🔔 The system is designed to address production irregularities quickly by using a call button.
• 🟡 A yellow lamp on the board signals an issue on the production line, alerting the leader to the problem.
• 🎶 A music-like siren is used to draw attention to the yellow lamp and the need for immediate action.
• 🏃 The leader rushes to the location upon seeing the yellow lamp to resolve the issue.
• 🔄 Production continues to move while the leader is addressing the issue, maintaining efficiency.
• 🚫 If the issue is not resolved in time, the assembly line will stop, and the lamp turns red to indicate a halt.
• 🛑 The red lamp signifies a complete stop in production until the issue is fully resolved.
• 🔄 Once resolved, the leader uses the call button to restart the production line, ensuring continuity.
• 🔍 Identifying and resolving issues promptly is crucial to prevent defective vehicles from moving to the next production stage.
• 🛠️ The system emphasizes quality control by ensuring that production is stopped if necessary to fix problems.
• 🔑 The call button serves as a key tool for both alerting to issues and signaling that they have been addressed.

Q & A

What is the purpose of the call button in the production process described in the script?

The call button is used by workers to signal an irregularity or issue during production, triggering a response mechanism to address the problem.

What visual indicator is used on the board when a worker presses the call button?

A yellow lamp is displayed on the board to indicate that an irregularity has occurred and requires attention.

What sound is associated with the yellow lamp on the board?

A music-like siren is triggered when the yellow lamp is displayed, alerting the leader to the issue.

What is the leader's responsibility upon seeing the yellow lamp on the board?

The leader must confirm the yellow lamp on the board and rush to the location of the issue to address it promptly.

What happens to the production line while the leader is addressing the issue?

The production line continues to move during the time the leader is resolving the issue.

What is the consequence if the issue is not resolved within a set time after the leader's arrival?

If the issue is not resolved in time, the assembly line will stop, and the board lamp will turn from yellow to red.

How does the leader communicate that the issue has been resolved and the production line can resume?

The leader presses the call button to release it, signaling that the issue is resolved and the production line can start moving again.

What is the primary goal of stopping the production line when an issue is identified?

The primary goal is to ensure that the vehicle moves to the next stage of production without any defects.

How does the system ensure quality control in the production process?

The system ensures quality control by requiring issues to be resolved before production continues, even if it means stopping the line.

What is the significance of the music in the script?

The music in the script serves as a background element to create atmosphere, but its specific significance is not detailed in the transcript.

How does the described system benefit the overall efficiency and quality of the production?

The system benefits efficiency by quickly addressing issues without extensive downtime and ensures quality by preventing defective products from moving to the next stage of production.