The Andon system, a pillar of Lean methodology, has evolved considerably since its introduction by Toyota. Today, manufacturers face a crucial choice: opt for a traditional manual Andon system or embrace automation. Each approach has specific advantages and disadvantages, and the optimal choice largely depends on the production context, the organization's Lean maturity, and its corporate culture. In a connected factory environment, these production alert systems play a decisive role in maintaining industrial performance and ensuring high quality. This article explores the nuances between these two implementations to help you make an informed decision in favor of continuous improvement of your processes.
Andon, a Japanese term meaning "lantern," is a visual alert system that allows for rapidly signaling anomalies in a production process. Its fundamental objective remains unchanged whether manual or automated: identify problems as soon as they arise, communicate them effectively, and facilitate their quick resolution in a continuous improvement approach.
You have probably already noticed that in many factories, these production alert systems appear as illuminated boards, sound signals, or stop cords. But with the advent of Industry 4.0, these traditional systems have undergone a significant transformation, becoming central elements of modern industrial performance.
In a manual Andon system, operators themselves trigger alerts via buttons, cords, or physical panels. When a problem occurs, the operator manually activates the signal, usually associated with a color code indicating the nature or severity of the problem. This quality alert system relies entirely on human vigilance and team engagement in the continuous improvement process.
Operator Empowerment: Manual Andon places operators at the heart of the quality system. They become the primary guarantors of quality, which strengthens their sense of belonging and commitment. This empowerment is often the cornerstone of a true continuous improvement culture. How does this empowerment influence the motivation and proactivity of your teams on a daily basis?
Implementation Simplicity: Wondering how to start with an Andon system? The manual version has the advantage of relatively simple and inexpensive deployment. A basic light board, a few buttons or cords, and you already have a functional production alert system.
Adaptability Flexibility: Manual systems can be easily modified or improved according to the specific needs of each workshop, without requiring specific technical skills in programming or automation.
Authentic Lean Culture: Manual Andon promotes human interactions and collaborative problem-solving, fundamental aspects of the original Lean philosophy and continuous improvement.
Dependence on Human Initiative: The system's effectiveness relies entirely on the vigilance and proactivity of operators. If they hesitate to report problems (for fear of reprimands or out of habit of working around difficulties), the system loses its effectiveness.
Potentially Longer Reaction Times: Between detecting a problem, manually reporting it, and intervention, several minutes can elapse, which can impact overall productivity and industrial performance.
Limited Traceability: Without an automated data collection system, analyzing trends and recurring problems can be tedious and less accurate, thus limiting the potential for continuous improvement.
Potentially Incomplete Coverage: Some subtle or progressive problems may escape the attention of operators until they become critical.
Automated Andon integrates sensors, industrial vision systems, and analysis algorithms to automatically detect anomalies. These production alert systems are typically connected to digital dashboards, mobile applications, or MES (Manufacturing Execution System) systems, characteristic of Industry 4.0 and the modern connected factory.
Early and Systematic Detection: Sensors and algorithms can identify anomalies even before they are perceptible to the human eye, allowing ultra-early intervention and strengthening continuous process improvement.
Optimized Responsiveness: Alerts are generated instantly and can be transmitted simultaneously to multiple managers via different channels (screens, smartphones, tablets), significantly accelerating response time in the connected factory.
Analytical Richness: Automation allows for collecting a considerable volume of data on incidents, their frequency, duration, and impact. This data constitutes a goldmine for analysis and continuous improvement of industrial performance.
Comprehensive Coverage: Unlike manual systems that depend on human vigilance, automated systems can continuously monitor all critical parameters.
Integration with Digital Ecosystems: Automated Andons easily integrate with other company systems (ERP, CMMS, etc.), creating a coherent and complete information flow, typical of Industry 4.0. Is your current infrastructure ready to integrate an automated production alert system?
Significant Initial Investment: Implementing an automated Andon represents a significant cost, including sensors, software, integration, and training.
Technical Complexity: These systems require specific skills for their configuration, maintenance, and evolution. You have probably already noticed that this complexity can create a dependency on external providers or require hiring specialized technical profiles.
Risk of Operator Disengagement: When technology takes over, operators may feel less involved in the quality process, which can weaken the continuous improvement culture.
Potential False Alerts: Automated systems can sometimes generate irrelevant alerts, which can create decision fatigue among supervisors if the phenomenon becomes frequent.
Technological Dependence: A failure of the automated system can temporarily paralyze anomaly detection if no manual backup system is maintained.
The choice between manual and automated Andon depends on several key factors:
Companies beginning their Lean journey will often benefit from starting with a manual system that promotes the appropriation of concepts and team engagement in continuous improvement. This type of implementation allows for a gradual increase in skills and natural integration into work habits. More mature organizations can fully benefit from automation, having already established a solid culture of quality and problem-solving. How do you evaluate your organization's current Lean maturity?
High value-added processes, high-risk processes, or those requiring extreme precision are more suited to automation and sophisticated production alert systems. In these contexts, the slightest deviation can have significant consequences on quality or safety. More artisanal productions, batch productions, or low-volume productions may favor the manual approach, where human expertise and judgment remain irreplaceable for maintaining industrial performance.
An organization that strongly values autonomy and human initiative might prefer to maintain a significant manual component in its Andon system. Conversely, a company already engaged in an advanced digital transformation and Industry 4.0 will naturally find it appropriate to integrate an automated Andon into its connected factory ecosystem. Cultural compatibility is essential to ensure the adoption and effectiveness of the system.
Beyond the initial investment, one must consider the resources needed to maintain and evolve the chosen system. An automated Andon requires specific technical skills, while a manual system demands constant supervision to maintain the discipline of use and team engagement in the continuous improvement process.
Your industrial performance objectives will also determine the choice of system. If your priority is maximum reduction of downtime and early detection of anomalies, an automated system will offer significant advantages. If the emphasis is on developing a strong quality culture and operator involvement, a manual or hybrid system might be preferable.
Many companies today adopt a hybrid approach combining:
This approach allows for benefiting from operator empowerment while exploiting the analytical capabilities and responsiveness of automated systems, thus creating an optimal continuous improvement environment. How could a hybrid solution specifically adapt to your production context?
Andon, whether manual or automated, remains a fundamental tool of Lean Manufacturing and an essential production alert system for any company aiming for operational excellence. The manual system offers simplicity, operator engagement, and flexibility, but has limitations in terms of responsiveness and analysis. Automated Andon, more aligned with the principles of Industry 4.0 and the connected factory, brings precision, responsiveness, and analytical richness, but requires a significant investment and can dilute human engagement if poorly implemented.
Rather than opposing these two approaches, the current trend favors their complementarity according to the 5 detailed criteria: Lean maturity, production nature, corporate culture, available resources, and strategic objectives. The important thing is to choose a solution aligned with your level of Lean maturity, your corporate culture, and your ambitions in terms of industrial performance. Remember that Andon is not an end in itself, but a powerful means of concretizing the philosophy of continuous improvement that is at the heart of Lean Manufacturing, by allowing you to identify, communicate, and quickly resolve problems for more efficient production of better quality.
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