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 complete display boards 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 Signal 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
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