autonomation

Autonomation, also called automation with a human touch, is a manufacturing concept that combines automatic equipment with human oversight to ensure quality. In autonomation, machines are designed to detect abnormal conditions and stop automatically, preventing defective output from moving farther along the production line. The operator then investigates and corrects the cause before production resumes. This approach aims to maintain high throughput while preventing defects at the source rather than relying on post-production inspection.

Historically, autonomation is closely associated with jidoka, a pillar of the Toyota Production System developed by Sakichi Toyoda and refined by Toyota. Jidoka emphasizes stopping the line when a problem is detected, enabling workers to address faults and implement improvements without allowing problems to propagate.

Techniques used in autonomation include sensors, alarms, vision systems, torque and temperature monitoring, and simple error-proofing methods known as poka-yoke. The combination of real-time detection and immediate stoppage reduces waste and supports rapid root-cause analysis. The concept also relies on standardized work and the empowerment of workers to halt equipment without fear, reinforcing a culture of continuous improvement and quality at the source.

In modern manufacturing, autonomation is often integrated with digital sensing, robotics, and data analytics, giving machines the ability to detect anomalies and prompt human intervention when needed. It serves as a bridge between traditional lean practices and contemporary Industry 4.0 approaches, balancing automated efficiency with human problem-solving and oversight.