Project Objective: The objective of this project was to introduce Jidoka to the four-station assembly line within the Toyota Production Systems Lab at the Rochester Institute of Technology.

Background Information: Jidoka is a term used in the Toyota Production System that refers to diagnosing an abnormality immediately and correcting it accordingly so that defects are not passed along to the next operator. An Andon system is a principal components of Jidoka.

Project Description: In order to improve quality on this line, two Andon systems and a corresponding monitoring system were developed.

Mechanical Andon Systems:Electrical Andon System with Monitoring:

Project Team:

Trevor Andrews Industrial & Systems Engineering Holli Monroe Mechanical Engineering Emily Piccione Industrial & Systems Engineering William Wright Mechanical Engineering

The project team would like to acknowledge and express appreciation to RIT faculty member Scott Bellinger for all of his help and assistance in executing this project.

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P13716: Andon System for Toyota Production Systems Lab

More information can be found at the following website: http://edge.rit.edu/edge/P13716/public/Home

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system photo here

Design Specifications:•Visible from 30 feet•Inexpensive•Simplistic design for ease of use•Accommodate additional stations

Andon System Particulars:•Team Member recognizes abnormality and initiates visual cue (colored cone or colored magnet). •Team Member subsequently initiates auditory cue (voice alert or bell). •The combination of cues prompts Team Leader to visit given station.

Design Specifications•Includes paced line capability•Global display tracks station status•3 activation modes, green, yellow and red•Each station accommodates NTID needs

Andon System Particulars:•Team Member recognizes abnormality and presses button. Button press triggers an automated response from PLC programming.•PLC program assesses station status and operates station lights accordingly.•LabVIEW interfaces with PLC to display real-time data regarding the statuses of stations.•Data mining capabilities created to promote future root cause analysis and preventative countermeasure development.