Andon systems, once reserved for large automotive companies like Toyota, are now accessible and particularly relevant for Quebec's manufacturing SMEs. These visual and sound signaling solutions significantly improve responsiveness to production problems while generating valuable data for continuous improvement. Today, Andon technology represents a strategic investment for Quebec factories seeking to optimize their operations in a context of increased competitiveness.
The Andon system originates from Japan, specifically from Toyota's assembly lines. You've probably already noticed these visual devices in modern factories - green, yellow, and red lights signaling the status of a workstation. But the story goes much further.
In the immense automotive assembly lines sometimes counting up to 400 workstations, Toyota developed a simple but revolutionary mechanism: a cord that operators could pull when facing a problem. As soon as an operator encountered a difficulty, they pulled this cord, triggering a visual signal indicating the location of the problem. A special team would then quickly intervene to resolve the situation before it paralyzed the entire production chain.
This visual signaling system in production revolutionized the automotive industry by enabling unprecedented responsiveness to production problems. But for a long time, these installations were costly and complex, with mechanical cords, light systems, and imposing display boards - an investment difficult to justify for SMEs.
Today, the situation has radically changed. Digitalization has transformed these once complex and expensive systems into affordable and easy-to-deploy Andon solutions. You might wonder how this technology has adapted to the needs of SMEs? The answer is simple: the digital tablet.
Modern Andon systems can now be deployed using simple tablets placed at strategic points in the factory. No need for complex mechanisms or costly installations. An operator encountering a problem can simply press a button on the touch interface, select the nature of the problem (machine breakdown, lack of material, quality issue...), and the alert is immediately transmitted to the concerned persons.
These modern factory alert systems go far beyond simple light signals. They can trigger:
This flexibility allows the Andon device to be adapted to the specific needs of each company, regardless of its size or sector of activity in the Quebec industry.
The primary advantage of an Andon system remains its ability to significantly reduce response time to problems. Take the example of a shipping station where an operator encounters a problem with their label printer. Without an Andon system, the classic scenario is as follows:
With an Andon system, the operator instantly signals the problem via the tablet, specifying that it's a printer issue. The system automatically alerts IT staff and the supervisor, who can intervene quickly. The time and efficiency gain is considerable for Quebec manufacturers.
The digital Andon board greatly facilitates communication between different factory actors. It eliminates intermediaries and allows direct and clear transmission of information. For SMEs that often operate with reduced and versatile teams, this improvement in communication represents a major advantage in the daily management of operations.
Unlike traditional mechanical systems, digital Andon solutions automatically generate valuable data:
This data becomes a real dashboard for continuous improvement teams, allowing the identification of systemic problems and prioritization of improvement projects with maximum impact.
For Quebec SMEs often concerned about the implementation costs of new technologies, modern Andon systems represent a minimal investment for maximum impact. The necessary equipment is limited to a few robust tablets (no need for high-end industrial models) and configurable software according to the specific needs of the company.
The savings generated by reducing downtime and improving productivity generally allow a return on investment in just a few months.
Another strength of modern Andon systems is their ability to evolve with the company. An SME can start with a simple configuration - a few tablets at critical stations with basic alerts - then progressively enrich the system with:
This scalability allows the investment to be adapted to the real needs and financial capabilities of the company.
Quebec factories present certain characteristics that make Andon systems particularly relevant. Facing the labor shortage affecting the entire province, these devices help optimize available human resources by reducing time lost looking for help or solving recurring problems.
Moreover, Quebec's manufacturing sector is characterized by a great diversity of companies, from small artisanal productions to medium-sized factories specializing in high value-added products. This diversity requires flexible and adaptable solutions, which modern digital Andon systems perfectly offer.
In the specific context of Quebec's industry, where the emphasis is on innovation and productivity to offset higher labor costs than elsewhere, Andon technology represents a strategic tool to maintain competitiveness.
How to install an Andon system in an SME? The choice of solution depends on several factors to consider:
Cloud solutions offer quick setup and simplified maintenance, ideal for SMEs with limited IT resources. Local installations may be preferable for factories with particular connectivity or security constraints.
Some systems favor mobile interfaces (applications on smartphones or tablets) while others rely on fixed stations at workstations. The choice will depend on the mobility needed by operators and the type of production environment.
Solutions vary considerably in their ability to adapt to the specific processes of the company. Some offer fully customizable interfaces while others propose more standardized but quicker to deploy configurations.
For Quebec manufacturers, the ideal is often to favor a solution that combines ease of use, evolution capacity, and good local support.
Quebec manufacturing SMEs face particular challenges: labor shortage, international competition, and the need to innovate to remain competitive. In this context, Andon systems represent a particularly suitable solution.
Implementation can follow a progressive approach:
This approach limits risks while maximizing the chances of project success.
Andon systems, once reserved for automotive industry giants, are now within reach of Quebec manufacturing SMEs. Thanks to digitalization and technology simplification, these visual signaling tools offer an excellent value-effort ratio for companies of all sizes.
In 2025, an effective Andon system can be deployed with minimal investment in hardware and configuration. The benefits are immediate: increased responsiveness to problems, reduced downtime, collection of valuable data for continuous improvement, and better use of human resources.
For Quebec manufacturing SMEs facing productivity challenges and labor shortages, implementing an Andon system represents a "quick win" - a low-risk, high-yield project that can serve as a springboard towards a more complete digital transformation of their operations. Andon technology thus constitutes an accessible and cost-effective first step towards the smart factory, particularly adapted to the realities of Quebec industry.
Sign up to follow manufacturing news.