Andon System in Manufacturing: Complete Implementation Guide

Meta Description: Learn what an Andon system is and how it improves manufacturing efficiency. Discover implementation strategies, benefits, and best practices for visual management.

Introduction

The Andon system is one of the most powerful visual management tools in manufacturing, originating from the Toyota Production System. It provides immediate visual and auditory signals when problems occur, enabling rapid response and continuous improvement.

What Is an Andon System?

Andon (Japanese for "lantern" or "paper lantern") is a visual management system that alerts operators and supervisors to problems in a production process. It enables immediate action to correct problems and prevent defects from moving downstream.

The Core Concept:

┌─────────────────────────────────────────────────────────────────┐
│                    Andon System Philosophy                       │
├─────────────────────────────────────────────────────────────────┤
│                                                                 │
│  "Stop the line to fix the problem at the source"               │
│                                                                 │
│  Normal State: [GREEN] - Running smoothly                      │
│  Problem State: [YELLOW] - Help needed / Issue identified       │
│  Stop State: [RED] - Line stopped / Problem being resolved      │
│                                                                 │
│  Goals:                                                         │
│  • Quality at the source                                        │
│  • Immediate response to problems                               │
│  • Visual management for all                                    │
│  • Continuous improvement data                                  │
│                                                                 │
└─────────────────────────────────────────────────────────────────┘

Andon System Components

1. Andon Cord/Buttons

Physical activation devices at each workstation:

Pull cord for immediate line stop
Push buttons for different issue types
Touchscreen interfaces for detailed issue reporting
Wireless pendants for mobile operators

2. Display Boards

Visual indicators visible across the production area:

┌─────────────────────────────────────────────────────────────────┐
│                    Typical Andon Display                         │
├─────────────────────────────────────────────────────────────────┤
│                                                                 │
│  LINE 1              LINE 2              LINE 3                 │
│  ┌─────────┐        ┌─────────┐        ┌─────────┐            │
│  │  ●●●    │        │  ●●○    │        │  ●●●    │            │
│  │         │        │ HELP:   │        │         │            │
│  │ RUNNING │        │ MATERIAL│        │ RUNNING │            │
│  │ 145%    │        │ 87%     │        │ 102%    │            │
│  └─────────┘        └─────────┘        └─────────┘            │
│                                                                 │
│  STATUS:             SHIFT:              DOWNTIME:              │
│  ● Green             Goal: 1,000 units   Today: 12 min          │
│  ○ Yellow            Actual: 945         This Week: 2.3 hrs     │
│  ● Red               Gap: 55                                    │
│                                                                 │
└─────────────────────────────────────────────────────────────────┘

3. Audio Alarms

Auditory signals to alert personnel:

Different tones for different severity levels
Zone-specific audio for location identification
Volume adjustable for environment

4. Software Integration

Modern Andon systems integrate with:

MES for data collection
CMMS for maintenance requests
Quality systems for defect tracking
Production planning for scheduling

Types of Andon Systems

1. Manual Andon

Traditional pull-cord or button system:

Simple and reliable
Low cost
Operator activated
Limited data collection

2. Automated Andon

Integrated with equipment:

Machine-activated signals
Automatic status detection
Rich data collection
Higher initial cost

3. Digital Andon

Software-based visualization:

Displays on monitors, tablets, phones
Real-time data from multiple sources
Remote visibility
Advanced analytics

4. Mobile Andon

App-based systems:

Push notifications
Mobile response
Remote monitoring
Flexible deployment

Andon Status Colors

Standard Color Convention

Color	Meaning	Action Required
Green	Normal operation	None - running smoothly
Yellow	Issue detected, needs attention	Support team preparing to respond
Red	Line stopped, problem being resolved	Immediate response required
Blue	Material shortage	Material handling needed
White	Quality issue	Quality team response

Some companies use additional colors:

Purple: Safety concern
Orange: Maintenance needed
Cyan: Production complete

Andon Process Flow

┌─────────────────────────────────────────────────────────────────┐
│                    Andon Response Process                        │
├─────────────────────────────────────────────────────────────────┤
│                                                                 │
│  1. PROBLEM OCCURS                                             │
│     Operator identifies issue (defect, jam, shortage, etc.)     │
│            │                                                    │
│            ▼                                                    │
│  2. ANDON ACTIVATED                                            │
│     Operator pulls cord or presses button                       │
│            │                                                    │
│            ▼                                                    │
│  3. VISUAL SIGNAL                                              │
│     Display changes color, audio alarm sounds                   │
│            │                                                    │
│            ▼                                                    │
│  4. TEAM RESPONDS                                              │
│     Supervisor/support team comes to assist                     │
│            │                                                    │
│            ▼                                                    │
│  5. PROBLEM RESOLVED                                            │
│     Fix implemented, verified                                   │
│            │                                                    │
│            ▼                                                    │
│  6. ANDON RESET                                                 │
│     Line resumes, data logged for improvement                   │
│                                                                 │
│  Target Response Time: < 1 minute (Yellow), < 2 minutes (Red)  │
│                                                                 │
└─────────────────────────────────────────────────────────────────┘

Implementation Steps

Phase 1: Planning

Define Objectives
- What problems do you want to catch?
- What's your target response time?
- What metrics will you track?
Map Current State
- Document current problem response process
- Measure current response times
- Identify where Andon will add value
Design System
- Select activation method (cord, button, touchscreen)
- Define status colors and meanings
- Plan display locations for visibility

Phase 2: Technology Selection

Consideration	Options
Activation	Pull cord, push buttons, touchscreen, voice
Display	LED towers, LCD screens, projectors, mobile
Integration	Standalone, MES-integrated, cloud-based
Budget	Manual ($5K-20K), Automated ($20K-100K), Digital ($50K+)

Phase 3: Installation

Install hardware at each workstation
Mount displays in visible locations
Install cabling/network infrastructure
Configure software integrations
Test all functions

Phase 4: Training

Training Topics:

When and how to activate Andon
Response team procedures
Data collection and analysis
No-blame culture reinforcement

Phase 5: Go-Live

Start with single pilot line
Monitor system performance
Adjust based on learnings
Expand to other areas

Andon System Benefits

Operational Benefits

Benefit	Description	Typical Impact
Faster Response	Immediate awareness of problems	50-70% reduction in response time
Less Downtime	Problems addressed quickly	20-40% reduction in unplanned downtime
Better Quality	Issues caught at source	30-60% reduction in defects
Improved Safety	Hazards signaled immediately	40-50% reduction in incidents
Data Collection	Problem tracking for improvement	Evidence-based decisions
Team Awareness	Everyone knows production status	Better coordination

Quality Benefits

Built-in quality (Jidoka)
Prevents defect propagation
Reduces rework and scrap
Improves first-pass yield

Cultural Benefits

Empowerment of operators
Transparency in operations
Team-based problem solving
Continuous improvement mindset

Best Practices

Best Practice 1: No-Blame Culture

Andon only works in a blame-free environment:

Celebrate Andon pulls as improvement opportunities
Never punish operators for stopping the line
Reward response teams for quick assistance

Best Practice 2: Clear Response Procedures

Document and communicate response protocols:

Andon Activated → [Who responds] → [Within what time] → [What to do]

Example:
Yellow Andon → Team Leader → Within 30 seconds → Assess situation
Red Andon → Team Leader + Support → Within 60 seconds → Resolve or escalate

Best Practice 3: Track and Analyze Data

Use Andon data for continuous improvement:

Most common problem types
Response time trends
Problem resolution success
Downtime analysis

Best Practice 4: Keep It Simple

Start with basic functionality:

Three status colors (Green/Yellow/Red)
Simple activation method
Clear display
Easy reset

Best Practice 5: Maintain the System

Regular maintenance ensures reliability:

Daily: Check displays and buttons
Weekly: Test audio systems
Monthly: Verify data logging
Quarterly: Full system audit

Andon Metrics

Key Performance Indicators

Metric	Formula	Target
Andon Activation Rate	Activations / Shift hours	Track trend
Response Time	Time to arrive at station	<60 seconds
Resolution Time	Time from activation to resolution	<5 minutes
First-Time Fix	Fixed on first response / Total activations	>80%
Line Stop Time	Total line stop time / Production time	<5%

Pareto Analysis

Track Andon activations by category:

Problem Categories (Typical Distribution):

Material Shortages:    35%
Equipment Issues:      25%
Quality Defects:       20%
Process Problems:      12%
Personnel:             5%
Other:                 3%

Focus improvement efforts on top categories

Modern Andon Innovations

Industry 4.0 Integration

Traditional Andon → Smart Andon

• Manual activation → Machine-activated signals
• Simple displays → Interactive dashboards
• Local visibility → Remote access via cloud
• Limited data → Rich analytics and AI insights
• Reactive only → Predictive alerts

Digital Andon Features

Real-time OEE display
Production tracking against goal
Work order integration
Video feeds of issues
Mobile app notifications
Historical trend analysis
Automated report generation

Common Implementation Mistakes

Mistake 1: Ignoring Andon Activations

Problem: Operators learn not to pull Andon because nothing changes

Solution: Respond to every activation immediately and consistently

Mistake 2: Blaming the Operator

Problem: Operator stops line and gets blamed

Solution: Celebrate problem identification; focus on process not people

Mistake 3: Poor Display Placement

Problem: Displays not visible to those who need to see them

Solution: Mount displays at eye level, in line of sight, with adequate lighting

Mistake 4: Too Many Status Colors

Problem: Confusion about what each color means

Solution: Keep it simple - start with Green/Yellow/Red

Mistake 5: No Data Collection

Problem: Activations not tracked for analysis

Solution: Always log activation type, time, resolution, and cause

ROI Calculation

Example manufacturing line:

Before Andon:
• Average problem response time: 8 minutes
• Unplanned downtime: 45 minutes/shift
• Defect rate: 2.1%

After Andon:
• Average problem response time: 1 minute
• Unplanned downtime: 20 minutes/shift
• Defect rate: 0.9%

Annual Savings (3 shifts, 250 days):
• Downtime reduction: 18.75 hours × $1,000/hr = $18,750
• Quality improvement: 1.2% × $10M revenue = $120,000
Total Annual Savings: ~$138,750

Andon Investment: $35,000
ROI: 396%
Payback: ~3 months

Conclusion

Andon systems are foundational to lean manufacturing and visual management. They transform problem response from reactive and hidden to immediate and visible. Success requires more than technology—it demands a no-blame culture and commitment to rapid response.

Ready to implement an Andon system? Contact us to discuss your requirements and design a solution.