Andon lean, what it is all about?

Andon one of buzz word in lean, despite it success in toyota. Few article clearly informed key aspect of andon. Also the main components of andon, Where it is Started the benefits also key Element of andon implementations.

In 1950’s As the one leading lean implementation, Toyota develop method to identify some problem within the production system. the idea was when a problem is detected, production lines stop, and an alert is displayed. This is to conjunction machine and human interaction on managing shopfloor.

Andon definition

 Andon meaning a Japanese word for signal illumination from traditional paper lantern.

Why is it called like that?

Since in early adoptions of Andon board at 1950’s using the lamp behind a glass which indicates problem in line productions. it has similar functions as a light indicator of problem machine.

Andon are key point of implementing The Toyota Production System philosophy, since there are Thirteen pillars of the Toyota Production System. Which the main two pillars were the Just-in-Time and Jidoka (autonomation) goals of the TPS are autonomation with human wisdom. Andon are major tools in Jidoka practice, one of Toyota production system pillar.

Andon Lean system principle

The main Idea of andon is identifying Baratsuki or abnormalities easier and faster. by deploying lights signal to ask for help.By doing so built in quality and Jidoka are implemented

The Andon are key Toyota pillar execution other than Jidoka in order to strengthen shopfloor managment or Genba Kanri.

These methodologies put practicality upfront when at that times data at shopfloor are quite lacking. Toyota pioneering shopfloor management of problem by using signal from lamps. with small things like this it gives a huge change since all abnormalities being captured and recorded or even problem detected before making higher cost of poor quality.

Today Andon is implemented in any sector of industry since the impact on managing the shopfloor were effective. From digital ecommerce like amazon to aerospace industry like General Electric. one of common ground fro the implementation were the principal of Andon, which is When a problem is detected, production lines stop, and an alert is displayed.

Andon lean Components

there are three main components of andon Lean. those component works to alert tho shopfloor management (Gemba kanri), regarding abnormalities that happens. The tree elements Of Andon Lean are evolving matching Industry trends.

Andon Cord or Call trigger

Andon system Started when operator call the button or the pulling cord. Any abnormalities such as minor stop, defects that happens also triggering the andon system. Ussually andon using cords tu case operator call for help. the cords installed in 6 meters long along the Line. however with technology advance also with safety  system Increased. There are many other type Of andon trigger.

One of example andon cord replacement were push button system. This is a pplicable for any Machineries that need to comply ISO Safety of machineries or IEC 13489 Regarding Safety Integrity level of interlock system. This new Standard are required for machineries in Europe region, However other area in the word are follows. Even tough implementing pushbutton create additional walk or Non Value Add motions. Safety risk and work assesment are important.

Source: Toyota Global

The next system of andon trigger were smart watch or wearables Internet of things. this is next Level ofthe game. Which will reducing safety risk also enable non value add motion walk. Wearables ccomes good in process which has many people operating manual labor such as assembly line. for operation, that stationed In the line better using push button since Payback period of IOT Implementation need to come inplace.

source : Global Nissan news

Andon lights

Second component of andon were Andon Lights. Andon lights Indicate the work Cell or wor station that needs assistance. The indication ligths placed in certain area that visible for Production and managements. There are three main color of andon lights.

The first Color Of ondon ligths were Green, this color Indicates everything woro work accordingly, whitout any interruptions. there are one typo Of Illumination during andon lights were Green Which is constant without any blink.

The second color of andon lights Were yellow, this color Indicates that there are any Interruptions within the line. Which consequences does not Causing the line to stop. The obstruction cause Compromised in line speed. And need some technical assistance from line Leader or supervisor.

The third color of andon lights were red, this color required the line to stop. Which the line leader or the maintenance technician need to como to assess the condition.

Andon Board

Andon board as one of andon system Component It was become  vital visual management tools in Shopfloor. Andon Board indicates which work Station status and which Station needed assistance. basically andon board Placed in visual appealing area that able to inform line leader or Line supervisor regarding Line States.

Source: Toyota Global

How Andon lean works?

In manufacturing processes one flaw occurred will compound the cost of poor quality. The andon system work because there is cord cable along the shopfloor line which indicates problem or needs assistance it may cause a line stop or just give indicating lights.

Operator facing abnormalities.

The first action triggering Andon system were operator found a problem or abnormalities. in automotive industry, abnormalities or problems are anything that deviates from standard. I can tell you that they had almost all kind of standard. Since one of key Pillar in TPS also standardized works.

Standardized work now become one of focus from all kinds of industry. Due to sales competition in ecommerce, many company increase more product SKU in order to keep market share. Facing market flexibility in product mix, this is triggering higher changeover which tend to rise scrap and defect.

Scrap & defect are something that eating away factory profitability, thus standardized work is important aspect to manage. To manage shopfloor standardized work, Andon are just one of kind system. In the bigger picture we will benefit more if 5s audit, Gemba walk and visual control in place.

Line stopped by pulling Andon cord.

The second step after operator found abnormalities Andon Cord are pulled, or sometimes in a form of push button in the machine panel are triggered to stop the line. This action causes the continuous line or machine process are stop.

After the line stopped the illumination lamp on andon board are designed to show warning to the shopfloor management. Andon board located in vital area which visible to all shopfloor manager and supervisor.

One of best practice Nissan Tochigi plant use smart watch as alert on AGV downtime to maintenance technicians. This allows more mobility to technicians and prompt response to specifics AGV stoppage points.

Latest news in Nissan they develop the smart watch as well to operator. Instead of cable cord each operator had feature in their wrist to put andon indicator which connect with plant MES system.

source : Global Nissan news

Manager & supervisor remove the problem.

Triggering by Andon Board light indicator the line shopfloor management go to gemba (actual place). It means he/she himself go to the place to see factual data on what is happening.

This is the strength of TPS, since usually the management reluctant to go to shopfloor. They not able to see the factual things. Just rely on report which might be had some information’s deteriorate.

Based on information’s above Andon Lean is not about cost and profitability, it is also about management and culture. Currently many companies implement gemba walk but I would say many things are not quite effective. To see some good tips, see our post on gemba walk.

Lean management should also cover the analytical thinking and factual based approach. By using A3 report to finalize the root cause analysis finally the management decide on how the line will continue using temporary measure.

Improvement incorporates standardized work.

Andon Benefit in the in lean manufacturing (Operation Metrics)

The main concept of lean manufacturing is made more with less resources and less wastes. This ideology can be implemented in Gemba as long as the wastes are identified. if you still remember about 7 forms of wastes in lean, one form of wastes is defect.

Improve Overall Equipment Effectiveness

OEE are vital indicator on how manufacturing operations effectively using the equipment with available timing. By identifying the problem and promptly countermeasure the machine breakdowns. It will eventually reduce the inefficiencies and abnormality.

Andon also help the Shopfloor management to track the Loses on OEE,  Whether it cane from minor stop, Quality defects, or machine failure. Andon trigger time  can be Used as OEE Ioses references database.

Improve Mean Time to Repair (MTTR)

Mean time to repair woro metric of now maintenance react given tho problem or breakdown arise. The formula were to divi de the breakdown time to repair with the number of breakdown event. This metric were widely used in manufacturing process.

By tracking MTTR wo able to understand how maintenance tech nician labor hours or working hours. Andon Gives more time to react for technician to identify which line are needed assistance more rapidIy. By doing do The technician able to allocate more time to Investigate and handling the breakdown.

Reduce Cost of Poor Quality

Andon also takes Part in Quality. by implementing andon and operator awareness of each Stages Quality criteria. Andon Can be used  as tools to Stop the line and take some time to validate the issue.

Andon Summary

As part of lean manufacturing tools Andon are good tools to visualize abnormalities. By utilizing Andon benefit can be reaped. However, there are very few people knowing how to do Andon successfully and also link to your operations KPI.