Weekly Lean Insights

Andon: The Lean Tool for Immediate Problem Resolution

What is Andon?

Andon is a visual management tool used in Lean Manufacturing that provides real-time status updates on the production process. It enables operators and workers to signal an issue immediately when they encounter a problem. The term "Andon" originates from the Japanese word for "lamp" or "light," emphasizing its role in illuminating issues for swift resolution.

Andon is often integrated into Jidoka, the Lean principle of "autonomation"—automation with human intelligence. Jidoka ensures that when a problem arises, the process stops until the issue is resolved, preventing defective products from moving further down the production line. Andon plays a key role in this system by providing the necessary signals for intervention.

Advancements in Andon Systems

Traditionally, Andon systems relied on manual pull cords or buttons to alert supervisors of issues. However, modern Andon systems have evolved significantly:

• Automated Andon Systems – Instead of waiting for an operator to manually pull a cord, sensors and AI-based monitoring systems detect anomalies in production (e.g., machine malfunctions, defects, or delays).
• Automated Line Stops – The system can automatically halt production when an issue is detected, preventing defects from propagating downstream.
• Real-Time Problem Localization – Advanced Andon systems provide precise location indicators on digital screens or dashboards, showing exactly where in the production line the issue has occurred, improving response time and efficiency.
• Integration with IoT and AI – Modern Andon systems can predict failures and schedule preventive maintenance, reducing downtime and improving overall equipment effectiveness (OEE).

Benefits of Andon in Production

• Immediate Problem Detection – Alerts management and teams to issues as they arise.
• Faster Response Times – Facilitates quick decision-making and resolution, minimizing downtime.
• Improved Quality – Prevents defective products from moving downstream, reducing waste.
• Enhanced Communication – Encourages collaboration between operators, supervisors, and engineers.
• Empowered Workforce – Allows frontline workers to take ownership of quality and process efficiency.

Types of Andon Systems

1. Light-Based Andon – Uses colored lights (green, yellow, red) to indicate process status.
2. Sound-Based Andon – Includes alarms or buzzers to grab attention in loud environments.
3. Screen-Based Andon – Digital dashboards displaying real-time production data and problem locations.
4. Manual Andon – Operators pull a cord or press a button to signal a problem.
5. Automated Andon – Sensors and AI detect anomalies and trigger alerts automatically, sometimes stopping the production line.

Real-Life Case: Toyota's Andon System Evolution

Toyota, the pioneer of Lean Manufacturing, initially implemented a manual Andon cord system, allowing operators to stop the assembly line if they detected a problem. Over time, this system has evolved into an automated Andon system that not only stops the line but also pinpoints the exact workstation experiencing the issue. This advancement has improved Toyota’s response times and production efficiency, ensuring that quality issues are addressed before defects escalate.

Applicability Across Industries

• Manufacturing – Ensures production quality and efficiency.
• Healthcare – Alerts staff on equipment malfunctions or urgent patient needs.
• Retail & Warehousing – Helps track inventory discrepancies or system failures.
• IT & Software Development – Used in DevOps for real-time system monitoring and failure detection.
• Customer Service Centers – Flags service bottlenecks or system downtimes for rapid response.