What Is an Andon System?
An Andon system is a visual‑and‑audible alert method that originated in Toyota’s lean manufacturing philosophy. It lets workers, supervisors and managers instantly signal a problem on the production line so that it can be addressed before it spreads.
How an Andon System Works
The core workflow is simple but powerful:
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Learn More- Problem detection – A worker presses a button, pulls a cord, or an automated sensor detects an abnormal condition.
- Signal activation – A light, sound, or digital message lights up on an Andon board or dashboard.
- Immediate response – The right support team (maintenance, quality, supply) is alerted and can stop the line or provide assistance.
- Root‑cause analysis – The event is logged for later review and continuous‑improvement activities.
Modern Andon solutions integrate with ERP, MES or cloud dashboards, turning a manual pull‑signal into a data‑rich alert that can be tracked in real time.
Key Components of a Modern Andon System
- Visual display – LED panels, digital boards, or web dashboards showing the status of each workstation.
- Audio alerts – Buzzers, chimes, or spoken messages that draw immediate attention.
- Activation devices – Manual pull‑cords, push‑buttons, or sensor‑driven triggers.
- Data logging – Automatic recording of time, location, and type of issue for later analysis.
- Integration layer – Connectors to MES, ERP, or financial dashboard tools for KPI reporting.
Benefits of Implementing Andon
- Faster problem resolution – Issues are stopped at the source, reducing scrap and re‑work.
- Improved safety – Immediate alerts can prevent hazardous conditions from escalating.
- Higher quality – Continuous visibility drives a culture of accountability and quality ownership.
- Data‑driven improvement – Logged alerts become a rich source for Kaizen and Six Sigma projects.
- Employee empowerment – Workers can stop the line without fear, fostering engagement.
Industry‑Specific Andon Examples
Automotive assembly
Each station has a pull‑button that lights up a central board. A malfunctioning robot arm triggers an automatic sensor alert, stopping the line and notifying the robotics team instantly.
Electronics manufacturing
Solder‑paste defects are detected by vision sensors. The Andon system flashes a red LED above the affected cell and sends a text message to the quality engineer.
Food processing
Temperature excursions are sensed by IoT probes. An audible alarm sounds, and the Andon dashboard records the event for traceability and compliance reporting.
Step‑by‑Step Recipe to Deploy an Andon System
| Step | Action | Tools/Tips |
|---|---|---|
| 1 | Map the production line and identify critical stations. | Use a simple flowchart; focus on bottlenecks. |
| 2 | Select activation devices (manual button or sensor). | Consider rugged push‑buttons for harsh environments. |
| 3 | Install visual displays (LED panel or web dashboard). | Connect to your automation workflow guide for quick integration. |
| 4 | Configure alert routing – who gets notified and how. | Use SMS, email, or push notifications. |
| 5 | Set up data logging and reporting. | Store events in a database; feed into KPI dashboards. |
| 6 | Train operators and supervisors on proper use. | Run a short “stop‑the‑line” drill. |
| 7 | Review alerts weekly and conduct root‑cause analysis. | Apply 5‑Why or fish‑bone techniques. |
Quick Andon Checklist
- ✅ All workstations have a visible Andon button or sensor.
- ✅ Central display updates in real time.
- ✅ Alerts reach the right support team instantly.
- ✅ Every event is logged with time, location, and description.
- ✅ Weekly review meetings are scheduled.
Next Steps
Ready to automate your alerts and turn every production hiccup into a data point for improvement? Discover practical tactics for workflow automation and faster issue resolution in the 101 Ways to Save Time & Automate Workflows guide.
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