How do you train and empower your team to use Andon and respond to signals promptly and correctly?

La capacitación como en todo ámbito es lo más importante, mi punto de vista al respecto es, proporcionar formación práctica sobre el manejo de los dispositivos y sistemas Andon específicos segun corresponda a la industria, maquinaria y demaás recursos, Andon no solo es visual sino auditivo. Por otra parte es aconsejable realizar simulacros regulares permiten a los miembros del equipo practicar la respuesta a las se?ales Andon y esto permite que los empleados no se estresen ante la toma de decisiones. Como en todo proceso de mejora continua el feedback es importante para medir desempe?o e identificar áreas de mejora.

Clearly explain Andon's purpose: to identify and resolve production issues immediately to prevent defects, improve quality, and increase efficiency. Highlight the benefits of Andon such as reduced downtime, increased productivity, improved product quality and customer satisfaction.

Los mejore resultados en capacitaciones Andon que he brindado ha sido conceptual práctico, es decir he llevado grupos de alumnos de todo tipo de industria a recorrer diferentes plantas y de esa manera asimilaron los conceptos. Tambien desarrollé una gamificación, con muy buen impacto.

Comprehensive Training: Provide thorough training sessions on the purpose, function, & significance of Andon. Hands-On Practice: Offer opportunities for team to practice using the Andon system in simulated scenarios to familiarize themselves with its operation & response protocols. Standard Operating Procedures: Develop concise SOPs outlining the steps to follow upon receiving Andon signals, ensuring consistency & efficiency in response actions. Continuous Feedback & Improvement: Encourage open communication & feedback loops to continually refine Andon response processes based on real-world experiences & insights from team. Empowerment & Accountability: Foster a culture of empowerment.

La alerta automatizada del problema/anomalía/resultado fuera de lo común debe ser obvia para todo el mundo. Dos claves: -Debe llama la atención de los trabajadores -éstos deben tener la formación y autonomía para solucionar el problema

Conduct in-depth training sessions on how to use the Andon system. This may include: - Practical demonstration of how Andon works. Identification of the types of problems that should be reported through Andon. - Step-by-step instructions on how to activate Andon in different situations. - Scenario simulations for team members to practice using Andon.

We implemented the Andon system in our production line and conducted initial training and monthly simulation drills. In one drill, a team member identified equipment malfunction, promptly flagged it using the Andon system and minimized downtime by escalating the issue to the technical support team. We improved communication during problem identification and enhanced our response times in subsequent actual incidents. Proper Andon system training empowers your team to handle issues proactively, ensuring continuous production and quality improvement and reinforcing a culture of transparency and collective responsibility.

For me, the key point is building trust to let them know that no problem is a problem, and this can be read in two ways… having no problems is a problem, as you might not be challenging the process as much as you could, and also that there is no issue having problems, actually celebrating that they were found.

Promote a culture of responsibility and empowerment, where each team member feels comfortable and responsible for activating Andon when necessary. Establish clear procedures and communication protocols to ensure Andon signals are responded to quickly and effectively. Provide regular feedback on Andon usage and publicly recognize team efforts when signals are triggered and issues are successfully resolved.

We implemented the Andon system to prioritize quality and efficiency. After initial training, I regularly engaged with team members during floor walks to discuss any issues flagged through Andon. We also introduced a monthly review session where team members presented cases using Andon. This became a cornerstone of our continuous improvement efforts, with team members recognized for proactive behavior. These steps empowered the team to use Andon effectively, contributing to our organization’s goals of maintaining quality and efficiency while fostering a positive workplace culture.

Monitoring and measuring the Andon system effectiveness necessitates implementing a monitoring system to track activation frequency, average response time, and problem resolution efficacy. Utilize performance metrics to assess its impact on quality, productivity, and uptime.

I implemented the Andon system and set up quarterly reviews to analyze data. We found that one production line had frequent alerts due to outdated equipment. By addressing this, we improved production efficiency. Simplifying the response protocol based on employee feedback enhanced resolution times and overall team satisfaction. Monitoring the Andon system systematically ensures it improves operational efficiency and product quality and fosters a proactive workplace culture, boosting morale and engagement.

Reviewing and enhancing the Andon system mandates periodic reviews to identify improvement areas. Solicit team feedback, make adjustments as needed, and integrate Andon usage with other continuous improvement practices like the Toyota Production System (TPS).

After a year of implementing the Andon system at our company, we conducted a review and found that while generally effective, response times lagged due to unclear communication protocols. To address this, we updated our SOPs, introduced additional training sessions, and implemented a new digital dashboard for real-time tracking. These steps helped maintain the Andon system and drive quality, efficiency, and employee engagement improvements.

I find important to mention, that leaders should act as servants of their team. Letting them know, that there is someone to support them when a problem arise, brings a team mindset, and starts changing the culture, which is the bottom line purpose of lean.