Statistical process control is needed to count and analyze the number of defects in the rejected items. This enables the
definition of the process variables that affect the quality of the product; Jidoka can then be introduced into this plant.
It is important to note that in some manufacturing industries, such as automotive painting and electroplating
industries, once a quality problem is identified on a final product, it has already appeared on many other products.
Even if a correct action is immediately taken at one stage of a multi-stage process, there will still be a certain number of
products with the same problem as those products have already been manufactured in the process after that stage [13].
Application of ‘Jidoka’ in the paint booth would lead to much better quality and much lower scrap rates.
A potential 10% in the produced items could be saved by a lower scrap rate.