The Andon system, originating from the Toyota Production System, allows for quickly alerting supervisors and support teams when a problem occurs on the production line. This Andon alert system, once complex and expensive to implement, is now accessible to manufacturing SMEs thanks to technological advances. Implementing an Andon for SMEs brings immediate benefits in terms of responsiveness and operational efficiency. This article explains how to effectively implement an Andon system in your company, what the concrete benefits are, and how to avoid common pitfalls.
Originating in Japan and perfected by Toyota, the Andon system was initially a simple but ingenious device: a cord that employees could pull when they encountered a problem on the assembly line. This action triggered a light or sound signal, immediately alerting supervisors that intervention was needed.
In the original automotive factories, each station on an assembly line of 400 positions could signal a problem. If an operator encountered a difficulty, they pulled the cord, and a special team quickly arrived to solve the problem before it affected the entire production.
You've probably already noticed these light signals (green, yellow, red) in modern factories – they are the direct descendants of this system, but today, technology allows us to go much further.
The main advantage of an Andon system is the responsiveness it offers. You might wonder how to measure this gain? Think about your current process: when an employee encounters a problem, how much time do they spend looking for a supervisor or another resource to get an answer? How long is production slowed down or stopped?
With an Andon system, this responsiveness goes, on average, from several minutes to a few seconds, significantly reducing downtime and improving overall equipment efficiency, a key concept in lean manufacturing.
Unlike systems of the past that required complex mechanical installations (ropes, physical buttons, wired light signals), modern Andon systems are now based on accessible technologies:
The value/effort ratio has become extremely advantageous, even for modest structures looking to optimize their industrial processes.
The digital aspect of modern Andon systems allows for collecting valuable data for your continuous improvement initiatives:
This data helps identify recurring problems and implement permanent solutions rather than simply reacting to symptoms, aligning perfectly with modern production management principles.
The most common mistake is wanting a perfect system from the start. Begin with a simple version:
You can then evolve your system based on observed real needs.
You don't need expensive industrial equipment:
This pragmatic approach allows for implementing an effective Andon while controlling costs.
An effective system must direct the alert to the right person:
Also plan for an automatic escalation system if no one responds within a defined timeframe, an essential feature for incident management in the manufacturing environment. With automatic escalation to a key resource, you will guarantee a response time for each call.
Team preparation is crucial for system adoption:
Good adoption by teams is the key to success for any Andon system.
The true potential of an Andon system reveals itself over time:
This approach fits perfectly into a logic of continuous improvement and optimization of industrial processes.
The ROI of a well-implemented Andon system is measured in:
Most manufacturing SMEs see a return on investment in less than 6 months.
Imagine an employee preparing packages and applying labels. If their printer stops working, instead of searching for help while stock accumulates at their station, they can simply press a button on their tablet, select "Printer Problem," and IT support immediately receives a notification. In a few minutes, this employee can expect assistance and potentially a return to production!
On an assembly line, different sounds or music can be associated with different stations. When the "Imperial March" from Star Wars sounds, the team immediately knows it's station 1 that needs help, even without looking at a screen. This creative approach to Andon signaling improves the supervisory team's responsiveness.
A quality control operator who detects a recurring problem can use the Andon system to simultaneously alert production and engineering, allowing for a coordinated and rapid reaction.
Don't try to do everything from the beginning. A simple system that works is better than a complex system that will never be completed.
Without adequate preparation, employees might either not use the system or use it inappropriately, compromising all the benefits of the Andon in your production management.
An Andon system is not an "install and forget" solution. It requires regular monitoring and adjustments based on actual usage to continue providing value.
The true return on investment comes from analyzing data for structural improvements, not just from quickly solving one-off problems. This is where the Andon system becomes a true lean manufacturing tool.
Implementing an Andon system in a manufacturing SME has never been as accessible as it is today. With inexpensive tablets, dedicated applications, and a progressive approach, even small structures can benefit from this methodology from the Toyota Production System.
The benefits are multiple: increased responsiveness to problems, reduced downtime, collection of valuable data for continuous improvement, and employee involvement in problem-solving.
By starting simply and evolving the system progressively, your SME can quickly implement this "quick win" and significantly improve its operational efficiency. Remember that the goal is not only to solve problems faster but also to use the collected data to eliminate recurring problems at their source, in a true approach to optimizing industrial processes.
A basic implementation can be completed in 2 to 4 weeks. This duration includes hardware installation, software configuration, and initial team training. Complete adoption and system optimization may take an additional 2 to 3 months.
Although the Andon system was born in the automotive industry, it adapts perfectly to all manufacturing industries: food processing, pharmaceutical, electronics, etc. The important thing is to adapt the configuration to the specifics of your production process and the types of problems encountered.
Yes, modern Andon systems generally offer APIs allowing integration with your existing ERP, MES, or CMMS systems. This integration allows for enriching the collected data and automating certain actions in response to alerts.
The main success indicators are: reduction in incident response time, decrease in downtime, increase in productivity, and improvement in quality. You should also observe better communication between teams and faster resolution of recurring problems.
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