1. Method Name

Andon System

2. Alternative Names

Andon lights, Andon board (from the Japanese word "andon"—paper lantern)

3. Brief Description

Andon is a visual control system that signals the status of the production process in real time and alerts operators to problems as soon as they arise. It most often takes the form of a light panel (Andon board) or a column (Andon stack light) that is visible from a distance.

4. Purpose / When to Use

It is used to immediately highlight abnormalities (quality issues, material shortages, machine malfunctions) and to call for assistance (from the team leader, maintenance, or logistics). It is a key element of the Jidoka (autonomization) principle, which enables every worker to stop the line if they discover a problem, thereby preventing the production of defective products.

5. Procedure / How to Apply It

1. Define statuses and signals: Assign specific meanings to colors (or sounds). The standard conventions are as follows:
- Green: The process is running smoothly, with no problems.
- Yellow/Orange: A problem has been detected; an employee needs help, but the line is still running. The team leader is called
.- Red: Serious problem; the line is stopped. Requires immediate intervention by a manager or maintenance staff
.- Blue/White: Material shortage; logistics is called.
2. Install the hardware: Install buttons or Andon cords at each workstation or machine so that the operator can activate a signal. Install central Andon boards or light towers so that they are visible to the entire team and management.
3. Create a standardized response process (Reaction Plan): Clearly define who is to respond to which signal, when, and what their responsibilities are. Without a clear response plan,
Andon is just a “disco.” 4. Train the team: All employees and managers must clearly understand the meaning of the signals and their roles in the response process.
5. Analyze the data: Collect data on the frequency and causes of Andon activations. This data is a goldmine for long-term improvement (e.g., through Pareto analysis).

6. A Real-World Example

On the assembly line, an operator notices that he has received a defective part. He presses the yellow button. A yellow light turns on above his workstation, and his station number appears on the central Andon board. The team leader immediately comes to the scene. If they can resolve the problem within a predetermined time (e.g., by the end of the cycle), the light turns off and the line continues running. If not, the team leader activates the red signal, the line stops, and the shift manager is called in to prevent further problems.

7. Benefits

- Immediate visibility of problems: Problems are not addressed at the end of a shift, but as soon as they arise.
- Empowerment of employees: It gives operators the responsibility and authority to monitor the quality of their work.
- Reduced downtime and error rates: Quick responses to problems minimize their impact
.- Improved communication: Replaces shouting and calling for help with standardized visual signals.
- Promotes continuous improvement: Data from the Andon system clearly shows where problems occur most frequently.

8. Risks / Limits

- Lack of a response plan: If no one responds to signals, the system loses credibility and will fall out of use
.- Culture of fear: If an employee is punished for using Andon (e.g., for stopping the line), the system will never work. There must be a “blameless culture
.”- Overuse: If the system is used even for trivial problems, it can lead to “noise” and signals being ignored
.- Technical failure: The system must be reliable.

9. Practical Tips

- Start simple: A simple system using colored flags or cards is enough to begin with
.- Pair the Andon with music: Some companies use different melodies for different types of problems, which is less stressful than sirens.
- Celebrate the use of Andon: Praise an employee who, by using Andon, identified a problem and prevented further damage. This reinforces the desired behavior
.- Andon in the office: The principle can also be applied in administrative settings, such as in software development to visualize task status on a digital board (red = blocked).