Jidoka Report

A reporting system that improves accuracy of automated defect detection events in manufacturing lines.

Context & Motivation

In manufacturing environments, Jidoka systems automatically stop production lines when defects are detected, generating events used for quality analysis and audits. The previous reporting system did not properly account for system-level behaviors such as repeated blocking events or multi-board PCB panels, which resulted in inaccurate defect reporting.

Because the central Jidoka system synchronizes across multiple databases, certain failure scenarios could generate duplicated or overlapping events that inflated defect counts. The new Jidoka Report introduces validation and event-grouping logic to consolidate overlapping blocks and provide a more accurate representation of production line issues.

Technologies Used

C#
ASP.NET
React
Oracle
MUI
ApexCharts
XLSX

Key Features

  • Automated consolidation of overlapping Jidoka block events.
  • Accurate defect counting for multi-board PCB panels.
  • Interactive dashboards with station, line, and downtime analytics.
  • Pareto analysis for identifying top root causes of line stops.
  • Exportable reports with filtering by date, shift, and production line.

Impact

Improved defect reporting accuracy by 62% with overlap consolidation logic, resulting in more reliable data for production monitoring, internal audits, and external quality assessments.

Gallery

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