Andon - Lean Six Sigma Glossary

Andon is a manufacturing term that refers to a system used in manufacturing plants to alert operators and managers of machine or process problems in real-time. The goal of an Andon system is to quickly identify and address issues, minimizing downtime and maximizing production efficiency.

History

The concept of Andon was first developed in the early 20th century by Taiichi Ohno, an industrial engineer at Toyota. Ohno observed that in traditional manufacturing environments, operators often continued to work on faulty machines, leading to wasted time and materials. He introduced the Andon system as a way to quickly identify and address machine problems, which ultimately led to the development of the Toyota Production System (TPS).

Types of Andon Systems

Visual: This system uses lights, signs, or other visual cues to alert operators and managers to machine or process problems.
Audible: This system uses sound, such as alarms or sirens, to alert operators and managers to machine or process problems.
Digital: This system uses digital displays or computer systems to alert operators and managers to machine or process problems. This type of system also allows for data collection and analysis. Such system can then be used to identify trends and improve overall production efficiency.

Benefits of Andon

Increased Production Efficiency: Andon systems are designed to quickly identify and address machine or process problems, minimizing downtime and maximizing production efficiency.
Improved Quality Control: Andon systems allow operators and managers to quickly identify and address quality control issues, which can lead to improved product quality.
Better Data Collection and Analysis: Digital Andon systems allow for data collection and analysis, which can be used to identify trends and improve overall production efficiency.

Implementation of Andon

Identify the goals and objectives of the Andon system.
Identify the type of Andon system that will best meet the goals and objectives.
Develop a plan for implementing the Andon system.
Train operators and managers on how to use the Andon system.
Monitor and evaluate the effectiveness of the system.

Example

One example of an Andon system in a manufacturing plant is a visual system that uses lights to alert operators and managers of machine or process problems. For example, a machine on the assembly line may have a light on it that is normally green. If the machine encounters a problem, such as a jammed part or low lubrication, the light will change to red. This immediately alerts the operator and supervisor that there is an issue with the machine. And they can take action to fix it. Additionally, the supervisor can use this information to track the frequency and duration of these machine stops. This helps then to identify patterns, and take preventative action to reduce downtime.

Andon is a powerful tool for increasing production efficiency, improving quality control, and collecting and analyzing data. Its implementation can be a key element in the success of any manufacturing plant. It is important to identify the goals and objectives of the Andon system, choose the right type of system, develop a plan for implementation, train operators and managers on how to use the system, and monitor and evaluate the effectiveness of the system.

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Sachin Naik

Passionate about improving processes and systems | Lean Six Sigma practitioner, trainer and coach for 14+ years consulting giant corporations and fortune 500 companies on Operational Excellence | Start-up enthusiast | Change Management and Design Thinking student | Love to ride and drive