How can you improve production visibility with Andon systems?

1 What are Andon systems?

Andon systems are a type of production control system that originated from the Toyota Production System, a lean manufacturing philosophy that focuses on eliminating waste and improving quality. Andon means "lamp" or "sign" in Japanese, and it refers to the use of lights, sounds, and screens to display the status of production processes, machines, and workers. For example, a green light might indicate that everything is running smoothly, a yellow light might signal a minor problem or a need for assistance, and a red light might indicate a serious issue or a stoppage. Andon systems can also include buttons, cords, or switches that allow workers to trigger the signals and request help or feedback.

2 How do Andon systems work?

Andon systems work by collecting and displaying data from various sources, such as sensors, PLCs, cameras, scanners, or manual inputs. The data can be related to different aspects of production, such as quality, speed, availability, inventory, or safety. The data is then processed and converted into visual and audible signals that are shown on boards, screens, lamps, or speakers. The signals are designed to be clear, simple, and easy to understand by anyone on the shop floor. The signals can also be linked to actions or responses, such as sending notifications, triggering alarms, stopping machines, or activating backup systems.

3 How can Andon systems improve production visibility?

Andon systems can improve production visibility by providing real-time feedback and information to all the stakeholders involved in the production process. Not only can they identify and resolve problems faster and more effectively, thus reducing downtime, rework, and waste, but they can also empower and engage your workers by giving them more autonomy and responsibility. Moreover, Andon systems can track and measure your performance by collecting and displaying key performance indicators (KPIs) and metrics that reflect your production goals and objectives, allowing you to evaluate your progress, identify gaps and opportunities, and implement corrective actions or improvements.

4 How to implement Andon systems in your production process?

Implementing Andon systems in your production process requires careful planning and execution. To ensure a successful implementation, you should define your goals and objectives, analyze your current situation, design your Andon system, test and validate it, as well as train and educate your workers and managers. When defining goals and objectives, consider what you want to achieve with Andon systems, the key problems or challenges to address, and the metrics or indicators to monitor and improve. Analyzing your current situation involves examining existing data sources and systems in your production process, as well as the gaps and limitations in data collection and display. When designing the system, think about the types and levels of signals you want to use, the colors, sounds, and symbols to assign to each signal, how signals will be displayed and distributed, and how they will be linked to actions or responses. To test and validate the system, you should verify that it is working correctly and reliably, measure the impact of it, collect feedback from users, etc. Finally, when training workers and managers on the system's purpose and function, explain how they should use and respond to signals as well as reinforce desired behaviors.

5 How to optimize your Andon system over time?

Implementing Andon systems in your production process is not a one-time event, but a continuous process of learning and improvement. To optimize your Andon system over time, you should monitor and review it regularly to identify strengths and weaknesses, as well as trends and patterns in data and signals. Additionally, you should update and adjust your Andon system as needed to incorporate new data sources, systems, or technologies. It is also important to involve and engage your workers and managers in the evaluation and improvement of your Andon system as well as share and celebrate successes. Finally, you should address any challenges or difficulties that arise with your Andon system.

6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?