The Andon system, originating from Toyota assembly lines, has become an essential tool in preventing quality defects in manufacturing production. Beyond the simple signaling lights that many associate with this concept, modern Andon represents a complete system for early detection and rapid response to quality issues. In 2025, technology has made these alert systems more accessible than ever for manufacturing SMEs, transforming how companies approach quality and real-time problem-solving for defect-free production.
Andon traces its origins to Toyota's automotive assembly lines in Japan. In its original form, it was a simple yet revolutionary system: a cord that operators could pull to signal a problem on the production line. When a worker encountered a difficulty that could compromise product quality, they pulled this cord, triggering an alarm and often a colored light indicating the location of the problem.
You've probably noticed that production alert systems have evolved considerably. From physical cords and lights, we've moved to touch interfaces, digital displays, and automated alerts. What was once a complex mechanical system has become an accessible and adaptable digital network.
The fundamental principle of Andon is based on the idea that a problem detected early costs significantly less to resolve than a defect discovered at the end of the line or, worse, by the customer. By allowing operators to immediately report any anomaly, Andon creates a first line of defense against quality defects.
Andon gives frontline workers the authority and responsibility to stop production if necessary. This approach radically contrasts with traditional methods where only supervisors had this power. You might wonder how this affects productivity. In reality, this empowerment increases employee engagement and improves overall quality.
In 2025, implementing an Andon system no longer requires massive infrastructure investments. A simple $200-250 tablet with an industrial case can serve as an Andon interface at each workstation. This technological democratization makes the tool accessible even to smaller manufacturing structures looking to implement an Andon system in an SME with a limited budget.
The application of Andon now extends well beyond traditional assembly lines. Any workstation in a factory can benefit from an Andon system, from shipping to quality control, maintenance, and logistics. Wherever a problem can occur, Andon can alert the right people.
Contemporary Andon systems are no longer limited to visual signals. They can send SMS, Teams notifications, emails, trigger robotic calls, or display alerts on large screens. Some companies even use customized sound signals, such as specific melodies associated with each station, allowing supervisors to immediately identify the source of the problem without even looking at a screen.
Modern systems integrate sophisticated escalation mechanisms. If a problem is not addressed within a defined timeframe, the system can automatically alert the next level in the hierarchy, ensuring that no call for help goes unanswered.
Unlike traditional systems that simply signaled a problem, digital Andon platforms record each incident in a database. This traceability allows documenting the history of problems, their causes, and the solutions applied, creating a valuable knowledge base for the company.
The digital aspect of modern Andon automatically generates detailed statistics:
This data directly feeds continuous improvement initiatives, allowing teams to precisely target problematic areas and measure the effectiveness of implemented solutions.
Advanced Andon systems of 2025 no longer just report existing problems. Through analysis of historical data, they can now identify trends and suggest interventions even before defects occur. This anticipatory capability represents a major advantage of the Andon system for manufacturing quality, allowing companies to adopt a truly preventive approach.
In the context of Industry 4.0, Andon is no longer an isolated system but an integrated component of the digital manufacturing ecosystem. It communicates with Manufacturing Execution Systems (MES), ERPs, and real-time performance dashboards. This interconnection allows a global and contextualized view of quality problems, facilitating more informed decision-making at all levels of the organization.
Implementing a modern Andon system does not require major transformations of existing infrastructure. Companies can start with a simple configuration and gradually evolve it according to their specific needs.
One of the great advantages of digital Andon platforms is their ability to evolve. A company can start with a basic alert system and progressively add more advanced features such as automatic escalation, predictive analysis, or integration with other management systems.
Andon has come a long way since the pull cords on Toyota assembly lines. In 2025, it represents an accessible, powerful, and scalable quality defect prevention tool for the manufacturing industry. Digitization has not only simplified its implementation but has also multiplied its potential by adding a valuable analytical dimension.
For manufacturing companies of all sizes, modern Andon offers a quick return on investment by reducing downtime, improving product quality, and providing critical data for continuous improvement. It's no longer simply an alert system but a true pillar of quality strategy, transforming each operator into an active guardian of production excellence.
In a manufacturing world where responsiveness and quality define competitiveness, Andon has established itself as an essential element of the smart factory, now accessible to all industry players. The future of defect prevention in manufacturing production undoubtedly lies with these modern Andon systems, which combine ease of use and analytical power to ensure optimal quality at every stage of the manufacturing process.
Sign up to follow manufacturing news.