Digital Andon represents the modern evolution of a system created by Toyota decades ago. This digital transformation, made possible through IoT technologies and Industry 4.0, allows manufacturing companies of all sizes to implement sophisticated alert and responsiveness systems at a lower cost. The digital Andon system integrates sensors, interfaces, and connected platforms to create a more responsive and intelligent production environment. This democratization now offers SMEs tools that were once reserved for large industrial groups.
Originally, the Andon system was remarkably simple yet revolutionary: in Toyota assembly lines, each worker could pull a cord in case of a problem. This action triggered a visual alert (often colored lights) allowing quick identification of the workstation in difficulty. A specialized team would then intervene to solve the problem without the entire line stopping for too long.
You have probably already noticed these famous green-yellow-red signaling systems in modern factories. These indicator lights are the direct legacy of this Japanese innovation that transformed the global automotive industry and then spread to all manufacturing sectors.
By 2025, digital Andon has evolved considerably. Gone are the complex and expensive mechanical-electrical systems. A simple tablet, often in a robust industrial case, is enough to replace all the traditional equipment. This digital transformation makes the system accessible to companies of all sizes, including manufacturing SMEs that previously could not justify the significant investment required by a traditional Andon system. The integration into the Industry 4.0 ecosystem allows interoperability with other technological solutions of the connected factory.
Digital Andon fully exploits the possibilities offered by the Internet of Things. A simple $200-250 tablet placed at a workstation allows problems to be reported instantly. You might wonder how this system compares to the old one? The difference is striking: instead of pulling a cord or pressing a physical button, the operator interacts with a touch interface that allows them not only to report a problem but also to specify its nature.
The operation of a digital Andon system is based on several interconnected components thanks to IoT technologies. When an operator encounters a problem on their line, they use the touch interface to select the type of incident (machine breakdown, quality issue, material shortage, etc.). The IoT system instantly transmits this information to a central platform that analyzes the nature of the problem and its urgency level. This platform then triggers targeted notifications to responsible persons through different channels. The incident is tracked in real-time until its resolution, with automatic escalations if necessary. This entire process generates data that feeds analytical dashboards for continuous improvement.
IoT integration allows for a diversification of notification channels:
This last feature is particularly ingenious: each station can have its unique sound signature. Thus, an experienced supervisor immediately recognizes the origin of an alert just by hearing the specific melody, without even consulting their phone or a screen.
The true revolution of digital Andon lies in its ability to generate actionable data. Unlike traditional systems that were limited to signaling a problem, the 4.0 version systematically collects and analyzes:
This analytical dimension transforms Andon into a true continuous improvement tool, allowing the identification of bottlenecks in production processes.
Digital Andon functions like an IT ticket system, but applied to the production environment. Problems are categorized, prioritized, and tracked until resolution. This traceability allows evaluation of intervention effectiveness and identification of necessary skills for support teams.
One of the major assets of digital Andon is its ease of implementation. The required hardware is minimal and affordable:
The value/effort ratio is particularly favorable, making these projects "quick wins" for companies seeking operational improvement.
A digital Andon system can start simply and then evolve progressively. You can begin with basic functionalities (simple alert) then add more sophisticated capabilities:
Digital Andon is not limited to production lines. It can be successfully deployed in all departments:
Wherever increased responsiveness to problems can generate efficiency gains, digital Andon finds its place.
Digital Andon perfectly represents how Industry 4.0 transforms proven concepts by making them more accessible, more flexible, and richer in data. What was once an expensive mechanical system reserved for large companies has become an affordable and scalable digital solution that even SMEs can deploy in their manufacturing digital transformation journey.
The beauty of this evolution lies in its fidelity to the original spirit of the Toyota concept: reacting quickly to problems, directly involving operators in quality, and continuously improving processes. But the digital version adds the valuable ability to analyze data to move from a reactive approach to a proactive approach, perfectly aligned with Industry 4.0 principles.
In a manufacturing context where every minute of downtime is expensive, digital Andon stands as one of the most cost-effective technological investments a company can make on the path to its digital transformation.
The implementation of a digital Andon system can be remarkably fast compared to other Industry 4.0 projects. A basic installation can be operational in 2 to 4 weeks, including software configuration, hardware installation, and initial user training. For more complex implementations with integration to existing systems (ERP, MES), the timeframe generally extends from 2 to 3 months. Companies often see a return on investment in less than 6 months thanks to reduced downtime and improved responsiveness.
The technical prerequisites for a digital Andon system are relatively accessible. The fundamental element is a reliable Wi-Fi network infrastructure covering the concerned production areas. Internet access is not always necessary if the solution is deployed on an intranet. Tablets or touch interfaces must be adapted to the industrial environment (resistant to dust, shocks, or humid environments depending on the context). On the software side, modern solutions generally operate in SaaS mode or can be hosted on medium-capacity local servers. Integration with existing systems (ERP, MES) is not mandatory at startup but can be considered in an evolution phase.
Sign up to follow manufacturing news.