Automatic line stop

A method for making a production process stop whenever a problem or defect occurs. On an automated line, sensors and switches detect an abnormality and stop the line automatically; on a manual line, a fixed-position stop system lets operators pull an overhead cord or press a button that stops the process at the end of the work cycle. It applies the lean principle of jidoka, preventing defects from passing to the next phase of production and avoiding the waste of making a series of defective items.

Source checked2/2 values · 2026-10-25Methodology

Specification

1 source

Kind	methodology
Origin	Lean manufacturing (jidoka)

Study notes

Two implementations are described: automatic stopping by sensors and switches on automated lines, and a fixed-position stop system on manual lines.
The manual fixed-position stop system uses an overhead cord or a push button and stops the process at the end of a work cycle.
The manual stop is intended for problems that cannot be fixed during the current cycle.
Purpose: prevent defects from going to the next phase of production and avoid the waste of making a series of defective items.
Contrast given: mass producers keep lines running to achieve high equipment utilization even when known defects occur repetitively and require rework at the end of the process.
The document cross-references Error-Proofing, Fixed-Position Stop System and Jidoka.

Safety

On a manual line, the stop takes effect at the end of the work cycle, not immediately when the cord is pulled or the button pressed.