Andon

What is Andon?

Andon is a visual method in Lean Management used to instantly signal production issues or irregularities. Originally developed in Toyota's Lean Production, Andon is one of the essential tools in process monitoring and control.

By implementing Andon systems, employees and production workers can be immediately alerted to disruptions in the production process, facilitating swift problem resolution and thus continuous improvement of production operations.

Functionality and Components of an Andon System

Typically, an Andon system consists of an Andon Board or signal lights that display the production status and operational condition. Such Andon Boards or lights use color signals like red, yellow, and green to visually represent the status of a machine or production line:

• Green Signal: Indicates that the production process is running smoothly.
• Yellow Signal: Signals a warning or a potential disruption that requires attention.
• Red Signal: Indicates a critical issue that requires immediate resolution.

A crucial component is the Andon Cord, a pull cord that a production worker can activate to immediately halt the production process in case of a disturbance.

This mechanism ensures that problems are escalated quickly and necessary resources for troubleshooting are provided.

Objectives and Benefits of the Andon System

The Andon system pursues several important goals in production:

• Transparency and Overview: The visual display of production status makes the entire process transparent for all involved. This allows employees to understand the state of production in real-time and respond more effectively.
• Quick Responsiveness: By signaling errors or disruptions immediately, problems can be resolved faster, reducing production downtime.
• Increase in Productivity and Quality: Early error detection and resolution enhance the quality of production and minimize unnecessary waste.
• Employee Accountability: The system promotes awareness and responsibility among production workers for the quality of their work, as they are directly involved in the problem-solving process.

Application and Integration in Lean Production

In Lean Production, the Andon system is a fundamental component for enhancing process optimization and product quality. Alongside other Lean Management methods, it ensures that production processes are smooth and efficient.

Introducing an Andon system can make production lines more orderly and quickly identify causes of errors, leading to sustainably improved production quality.

Andon in the Context of Digital Manufacturing

With the increasing digitization in manufacturing, modern Andon systems can also be equipped with real-time data and automated alarm notifications. The status of a machine can be displayed directly on digital display boards or mobile devices of the employees.

This digital extension of the Andon system allows disruptions to be reported not only visually but also via email or phone, enhancing the efficiency and response speed in addressing production problems.

Challenges and Developments in the Andon System

Although the Andon system enables high efficiency and responsiveness in production, it also presents challenges. For instance, an excessive number of Andon signals or warnings can overwhelm employees and lead to inefficient production processes.

To counteract this, modern Andon systems are increasingly equipped with analytical functions to better understand the causes of frequent disruptions or false alarms and to address them effectively.

Conclusion: Andon as a Key to Process Improvement

The Andon system is a vital method in Lean Management that supports the continuous improvement of production processes through fast and transparent problem detection. By leveraging visual and digital signals, the system ensures optimized process control, reduces downtime, and enhances efficiency and quality in production.