What is Andon in the Lean Manufacturing System?
Spot and resolve issues using the Andon system in lean manufacturing. Minimize disruptions and keep operations running smoothly.
Quality
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Spot and resolve issues using the Andon system in lean manufacturing. Minimize disruptions and keep operations running smoothly.
Andon originates from a Japanese term meaning “paper lantern,” with a more accurate English translation as “sign” or “signal”. In lean manufacturing, Andon is a visual management system used to easily determine and display the status of production lines. The concept is an evolution from the Jidoka methodology of the Toyota Production System (TPS). The Andon system works by pulling the Andon cord to signal problems encountered or assistance requested, changing the color of the Andon light, and reflecting the update on the Andon board. It aims to alert about issues in real-time so solutions can be implemented immediately, decreasing downtime and saving costs.
Previously, production personnel left their posts to look for solutions, but with Andon, the solution is brought directly to the working area. It is a system that has been tried and tested to streamline workflows. Generally, Andon works through an interconnected network of three primary components: cord, light, and board. Listed below are what they mean and how they function:
The Andon cord, cable, or rope is usually located at the overhead of assembly line workers. When pulled, it means that a production operator requires support because a problem has been identified. In some settings, the cord manifests as a button or switch. Whatever the case, its purpose remains the same in alarming others of an issue that has been spotted.
The act of pulling the cord or pressing the button also triggers the Andon light of that specific equipment or production line. The change in color helps responders quickly determine the area that needs their assistance. While other types may have additional colors such as blue and white, a simple light system displays three main colors: green, yellow or amber, and red.
Green means production is normal or running smoothly, so continue with work as usual.
Yellow or Amber means a problem has been identified, so respond to the signal and help the operator fix the problem or perform product quality checks.
Red means production has been stopped, so investigate with the team leader or refer the problem to managers and fix it before continuing production.
Each with their appropriate color codes, the status of production lines automatically gets updated on the Andon board. It is a single source of truth for current manufacturing conditions. At a glance, supervisors and factory workers can view production targets, actual numbers, and total downtime, if any, fostering a culture of transparency and accountability.
Seeing Andon in action can help demonstrate exactly how the system works. When it comes to putting the principle into practice Toyota is well-known for taking the lead. Here is a real-life example of Andon in the workplace:
In Toyota, Andon functions as an alert system that can lead to a line stop. By using the cord which typically comes with an alarm sound, the Andon board lights up and team leaders get notified about an issue in a specific production line. If it cannot be resolved within a certain amount of time, then the line stops. Every Toyota employee can stop the manufacturing line if they perceive something as a threat to vehicle quality.
Example of Andon in Toyota | Image Source
As a visual control system applied in lean manufacturing, Andon can increase production levels by taking the time to look into problems and making the effort to fix them before they escalate. By sustaining its principles in daily operations, manufacturers can gain these significant benefits:
Empower frontline workers through an environment of openness and trust.
Accelerate teamwork by democratizing the ability to make decisions in production.
Maximize raw materials and reduce the manufacture of defective items.
Standardize product quality before it moves further down the line.
Improve customer satisfaction and enhance value to end users.
Taking inspiration from traditional paper lanterns, Andon has evolved into an innovation not only for industrial use but also for commercial use. Today’s technology has played a vital role in making it easier for businesses to strengthen and scale the system. Mitti (by SafetyCulture) is an operations management platform that can help teams respond to issues faster and work better together. Here’s how Mitti (by SafetyCulture) can support Andon implementation:
Boost employee reporting through the Mitti (by SafetyCulture) Issues feature. With the mobile app, capture key information as soon as problems arise, so your team can handle them before they spiral out of control. Using the web app, manage issues with ease as you can view their status and updates from a user-friendly dashboard. Managers can ensure that all issues identified through Andon are properly documented and accounted for.
Promote a culture of collaboration through the Mitti (by SafetyCulture) Actions feature. Displayed in a timeline that looks like a conversation, teams can chat and attach photos to assigned actions with priority levels and due dates. Opening Mitti (by SafetyCulture) on your desktop or laptop enables you to access all corrective actions in easy-to-understand charts to help track areas of improvement and keep compliance records. You can add up to 10 team members using your free Mitti (by SafetyCulture) account.
Creating a strong safety culture and streamlined operating system is more than just establishing a clear set of work instructions. It’s about making sure that your workforce understands those guidelines, so they can get the job done right without putting themselves or their colleagues at risk. Mitti Training can help you do just that.
A good and effective Andon training lesson can help communicate to your workers the importance of following their work instructions. It can take them through the step-by-step process of how to carry out their tasks safely and effectively, bringing everyone on the same page when it comes to workplace safety.
Embracing the lean approach to manufacturing can elevate your quality standards and launch your organization to achieve operational excellence. To help teams get started in implementing Andon, consider downloading and using lean manufacturing checklist templates for free.
