Implementing Jidoka in Software Development: Preventing Faulty Code from Reaching Production

In light of a significant OS outage that affected approximately 8.5 million devices, it's evident that a shift in mindset regarding quality is crucial. Quality is not achieved by chance but through constant reinforcement of discipline, combining people, processes, and technology. Drawing from my experience as a past instructor of the Toyota Production System (TPS) , where I taught the concept of jidoka or built-in controls to prevent problems, we can apply these principles to the Software Development Life Cycle (SDLC) to prevent similar incidents.

Jidoka: Built-In Quality from Manufacturing to Software Development

Jidoka is a cornerstone of TPS, emphasising the detection and correction of issues at their source. In manufacturing, jidoka ensures that problems are identified and addressed immediately, preventing defective products from progressing. For instance, a 4.5-ton metal press machine can only operate if the operator's hands are both on the control panel, ensuring safety and preventing accidents. Similarly, you cannot inject diesel into a gasoline-powered car because the nozzle won't fit—a built-in control preventing errors.

Applying jidoka to the SDLC involves integrating preventive measures that catch and address issues early in the development process. Here are some ways to implement jidoka in software development:

Automated Testing: Utilizing advanced automated testing tools is akin to jidoka in manufacturing, where machines are equipped with sensors to detect anomalies. These automated tests serve as built-in controls, ensuring that defects are caught before they progress further.

Rigorous Code Reviews: Just as jidoka involves immediate inspection and correction of defects, rigorous code review protocols by experienced developers can catch potential errors and ensure adherence to best coding practices. This peer-review process acts as a safeguard, where defects are identified and addressed immediately, preventing them from moving forward.

Phased Rollout Strategy: A phased rollout strategy mirrors the jidoka principle of stopping production to address problems before they escalate. Deploying updates incrementally allows for early detection and resolution of issues on a smaller scale before full-scale deployment. This approach helps to mitigate risks by ensuring any defects are contained and rectified early.

Continuous Monitoring: Continuous monitoring and anomaly detection systems in software development are similar to the real-time monitoring of production lines in manufacturing. These systems offer early warnings of post-update issues, enabling prompt corrective actions. Continuous monitoring acts as a quality control measure, ensuring that any deviations are quickly identified and rectified, much like how jidoka ensures ongoing quality assurance.

Strategic Recommendations for Future Mitigation:

Blue-Green Deployments: Adopting a blue-green deployment strategy minimises disruption. This approach involves rolling out updates to a subset of users (green environment) and monitoring the results before deploying to the broader user base (blue environment). It provides a controlled environment to identify and resolve issues before widespread impact, ensuring quality and stability.

Enhanced Incident Response Plan: Developing a more robust incident response plan that includes clear protocols for immediate action, communication, and recovery in the event of a deployment-related outage ensures swift containment and resolution of any future issues.

Final Thoughts:

By incorporating the principles of jidoka into the SDLC, we can create a development environment where quality is built-in, and issues are detected and addressed at their source. This proactive approach can prevent incidents like the recent OS outage, ensuring that our software systems are robust, reliable, and secure.