Andon
Andon signals and Andon systems in manufacturing and process operations
Andon is the Japanese term for a signaling system within a production process or plant which provides real-time information about the status of a production processes to both workers and managers. These signals and displays are intended to alert those workers and managers if there is a deviation or inconsistency in the production process to take corrective action.
The Japanese use Andon systems as a communication tool to communicate the status of a production line or process to all production employees on the production floor. These systems are usually found in many forms, from simple status lights or traffic light systems to a complete Andon board in visible locations around the production plant. They are a common tool in the automotive and component production industry where they are an integral part of the Toyota Manufacturing system.
Andon display boards usually display a more comprehensive set of signals, KPI’s or data about the production process. They can vary in size and KPI’s displayed, some are illuminated, have led displays, or are flat screens presenting production or process data in live real time.
These signals help the process workers communicate with production supervisors and factory managers. They also aid in quality control by having the ability to stop production and tackle quality issues as soon as they are identified and signaling other workstation operators and supervisors of the stoppage.
Andon signals and Andon board components
Andon signals and board components can vary from process to process and applications are countless, but generally will be used to communicate information to the production plant like the following:
– Production line status: producing, stopped, overload or idled, waiting,
– Workstation status
– Production settings such as temperatures, pressures, weights, speeds, electricity or gas/fuel consumption including trend lines
– Production unit counter
– Different times: current time, downtime, running period time, cycle times
– Production volumes, WIP and products produced
– Call signs for supervisors and managers to a certain area
– Different production KPI’s or goals such as planned production.
The Japanese auto manufacturers and other organizations which have implemented these systems throughout their production processes have found them to be very useful and a contributing factor to their company cultures, efficiencies, and lean manufacturing initiatives.
Andon Board Example in Manufacturing
An example of an Andon Signal display board which would be found in a production process is depicted below. Notice the use of colors in the status lights and setting readings. Color coding is an important characteristic of these signals as different colors may have different meanings and prompt actions by process operators and supervisors on the production line.
In the board below we can see different types of signals and information:
Time information: Different time values are displayed for the production line including current time of the day, run time and down time
Production line status: The status of each workstation through traffic lights, conveyor and overall production status
Production line/machine settings: The kiln temperature, line speed and overall production status
Note: It is important not to clutter the board with too many different signals, lights or data as it becomes harder to read for all users.
This board would be displayed on the production line or in an easy to view place for all process operators and supervisors to see easily.
Andon Signals examples
Andon signals can come in different forms, sizes and display a wide variety of information or statuses but serve the same purposes which is to convey information in a visual manner to alert production staff and supervisors to take action or understand what is happening in the production line very quickly.
Below we can see some further examples of Andon signal examples:
The example on the left easily displays the location of the production so factory staff can see which deck is currently carrying production.
The example on the right is a simple status condition for a production line
Steps in implementing Andon signals for a work station or process
Selecting the correct Andon signals for a manufacturing process involves understanding the specific needs and challenges of the process, the production line and workstation layout as well as considering what do you want to communicate about this particular work station or part of the process.
The aim of implementing a signal system is typically to improve efficiency, enhance communication on quality, and safety. Here’s a step-by-step guide:
1) Identify if the workstation requires to have an Andon Signal?
Does your factory have many production steps or complex in process workflow?
Is it difficult to observe this workstation or process step if there is an issue?
Does a particular part of the process and/or workstations consume critical resources that have great impact on cost and productivity?
Does a particular process step or workstation output quality has a great bearing on finish product quality?
Can this step in the production process become a bottleneck?
If the Answer is yes to all the above, this particular workstation or step in the process would benefit from the implementation of a Signal system or signal board. Proceed to further steps below.
2) Identify Key Metrics to communicate as part of the signal, Determine the key performance indicators (KPIs) and metrics that are critical to monitor for the manufacturing process step or workstation. These could include metrics such as cycle time, defect rate, machine downtime, inventory levels, or any other relevant measures.
3) Define Andon Triggers for that particular step of the production process, Based on the identified metrics and potential failure points, establish clear triggers or thresholds that will activate the Andon system. Lower and upper control limits in certain KPI’s identified in the previous step can act as trigger points. These triggers should be actionable and indicate when intervention or attention is required.
4) Select Visual and Auditory Signals, Choose appropriate visual and auditory signals for the Andon system. Visual signals can include colored lights (e.g., red for stop, yellow for caution, green for normal operation) or digital displays, while auditory signals can be alarms or chimes. Ensure that these signals are easily recognizable and intuitive for operators.
5) Prioritize communication of Signals, Determine the priority levels of different Andon signals based on the severity and impact of the issues they represent. For example, a critical quality defect might trigger an immediate stoppage of the production line, while a minor issue might prompt a visual alert for operators to investigate.
6) Implement and test the effectiveness of the signal system with feedback from production staff and management.
The Signal system or display board can be a work in process once implemented. It can be as simple as a traffic light or as complex as a display board with cycling live data and KPI’s on the production process. It is important to not lose focus on the objective of the signal and always keep communication efficiency in mind.
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