How to implement an Andon system to speed up information flow

Implementing an Andon system is a smart decision for companies in charge of manufacturing products, as its main function is to alert operators and managers to current problems in the process by automating the flow of information.

The term Andon comes from Japanese "paper lanterns" and was used at Toyota as warning signals to improve their response time. The main objective of implementing an Andon system is to improve the flow of information in case of problems, because in all factories unforeseen events occur that can delay or stop production.

A good company is able to solve problems quickly, safely and eliminate the root cause of the problem, so Andon can help with that process by standardising and speeding up the flow of information. Therefore, enabling a faster response with less wasted effort when transmitting information.

Andon functions as an input and output device which accelerates the flow of information. related slowdowns, production system stoppages and the implementation of an Andon system in various ways:

1. Andon CordonAlso known as the Andon line (in Japanese) or the Andon rope, this is a rope that hangs from the ceiling in case a problem occurs the operator pulls the rope and the system gives a signal. Usually a second pull cancels the signal and tells the Andon that the problem is solved.
2. Button of an Andon stationIn the value stream, each station in the value stream has its own button or wire, which allows the system to detect if there has been a problem and where it occurred, it is also possible to have more than one cord or button. For example, you could have a yellow wire if the operator has a problem and in case he is not sure he can fix it in time without stopping the line the operator pulls the red wire to signal the line to stop.
   Another option for the line stop is also to keep the line moving until the product has reached the end of the individual station. Only when the "time is up" does the line come to a complete stop. This allows calling for help while the line is still moving, and therefore creates less inconvenience for other stations.
3. Cordon Andon Multi StationBy implementing an Andon system with multiple cables, buttons and stations, it is possible to detect whether all the necessary operations have been completed, as there are often tasks left open and if time is running out, it means that the worker is falling behind or has forgotten something. 

In any case, it is a problem and a signal can be sent automatically. Similarly, for an automatic or semi-automatic machine, sensors and programmed logic can detect a current or even a possible upcoming slowdown or stop. This information is also forwarded to the Andon system.

However, before implementing an Andon system make sure you don't overdo it with the number of lines and the amount of input, as one line is a good starting point, more than three lines is excessive, and you don't want the operator writing a problem report while the line is waiting for him to actually fix the problem!

It is important to mention that there are many Andon systems to reduce response times in factories which also automatically measure things like production speed, actual and target quantities, and other parameters relevant to line performance.

Implementing an Andon system allows data on production performance to be received from different sources, such as sensors, programmes or manual inputs and this data is displayed, usually visually with lights, but also possibly in numbers or even audio signals or via mobile phone networks. As such, Andon can be part of visual management.

Probably the simplest Andon system is a stackable or industrial light tower on top of a machine, because one or more lights indicate the current status of the machine and even combinations are possible (green light on, yellow light flashing). 

When implementing an Andon system, the most common colours of alerts must be known:

• Greens for regular operations.
• Red for larger problems or defects (or, alternatively, a call for assistance).
• Orange for warnings.
• Blue for a request for assistance.
• White if all other colours are not enough for you.

Andon boards before implementing an Andon system in your factory

Andon boards summarise information about the status of the production system via a board that can create signals using different lights and LED number displays. Alternatively, you can also simply use a large screen monitor and program all display functions in the software. 

It usually shows the status of the different processes in the system and an actual and target production value, as well as problems with the number of defects, efficiency or material supply, and is flexible to add anything that is thought to be useful. 

One of the advantages of implementing an Andon system is that it is not limited to a single table and can automatically stop the line or process. For example, if the operator pulls the red Andon cable, the line stops until the problem is solved. This is one of the outputs of an Andon system, and also one of the automatic responses that a good Andon should make in case of problems.

If you want to know about the features of a system for production monitoring in the food industry before you implement an Andon system, subscribe to the Technology for Industry NewsletterThe new newsletter will keep you informed about new solutions available on the market to optimise your plant operations.