How do you design an effective Andon system for your lean manufacturing process?

1 Benefits of Andon systems

Andon systems can help you achieve several benefits for your lean manufacturing process, such as faster detection and resolution of problems, increased accountability and empowerment of workers, enhanced communication and collaboration among workers, supervisors, and support teams, improved visibility and transparency of the production process, and higher customer satisfaction. With Andon systems, you can reduce downtime and defects, stop the line and request assistance when needed, monitor performance and identify improvement opportunities, and deliver products with higher quality and reliability, meeting customer expectations and deadlines.

2 Types of Andon systems

When it comes to Andon systems, there are various types depending on the level of automation and complexity of the production process. Manual Andon systems require workers to manually activate a light or a button to signal a problem or request for help. Automatic Andon systems, on the other hand, use sensors or machines to automatically trigger a signal when they detect a deviation or fault. Lastly, computerized Andon systems integrate signals with software or databases that track and display data and information about the production process and the issues.

3 Design principles of Andon systems

Designing an effective Andon system for your lean manufacturing process requires following some basic principles, such as simplicity, visibility, responsiveness, feedback, and continuous improvement. The system should be easy to use and understand, with clear and consistent signals and codes. It should also be visible and audible to all relevant parties, with adequate lighting and sound levels. Additionally, the Andon system should prompt immediate and appropriate actions, with defined roles and responsibilities and escalation procedures. Furthermore, it should provide feedback and confirmation of the issue resolution, with indicators and reports of the results and outcomes. Finally, the system should be regularly reviewed and updated, with feedback and suggestions from the users and the customers.

4 Implementation steps of Andon systems

To implement an Andon system for your lean manufacturing process, you should first define the objectives and scope of the system, based on customer needs and process characteristics. Then, identify the types and sources of problems or abnormalities that you want to detect and resolve with the Andon system, and their impact and frequency. After that, select the type and features of the Andon system that best suit your process and your problems, and the signals and codes that you want to use. Once the system is installed and tested, ensuring its functionality and reliability, you should train the users and the responders. Finally, monitor and evaluate the Andon system, measuring its performance and effectiveness, and collecting feedback and data for improvement.

5 Best practices of Andon systems

To make the most of your Andon system for your lean manufacturing process, you should involve and empower your workers, support and coach your supervisors and managers, align and coordinate your support teams, and communicate and collaborate with your customers. Encourage your workers to use the Andon system and to participate in problem-solving and improvement activities. Make sure your supervisors and managers respond promptly and positively to the Andon signals and to the workers' needs and concerns. Ensure your support teams have the skills and the resources to assist and resolve the issues quickly and effectively. Inform your customers of the Andon system and its benefits, and seek their feedback and satisfaction.