Manufacturing Solutions Blog

A Deep Dive into the Andon System

In today's fast-paced manufacturing world, real-time visibility and rapid response to problems are no longer optional â€” they are crucial. That's where an Andon system comes into play. Essentially, an Andon system is a communication and alert tool â€” both visual and auditory â€” that empowers frontline workers, supervisors, and management to detect, respond to, and resolve issues as they arise, thereby minimizing downtime and boosting productivity.

What Is an Andon System?

Originating from the Toyota Production System, the term andon in lean manufacturing refers to a signaling system (literally "light" in Japanese) that alerts when abnormalities occur during production.

An Andon device commonly comprises:

Stack lights or tower lights â€” typically multi-colored (e.g., green, yellow, red) to represent different states.
Buttons, cords, or sensors â€” which operators or machines can trigger to raise an alert.
Andon boards or dashboards â€” digital or analog displays showing the status of multiple workstations or processes.
Alarms / audio signals â€” to grab attention quickly when a problem arises.

Modern Andon systems often integrate IoT, cloud-based analytics, and wireless communication to make the device smarter and more connected.

How Does the Andon System Work?

Here's a typical workflow for an Andon system in a manufacturing setup:

1. Problem Detection

An operator notices a defect, shortage, or safety concern.
Or, a sensor on a machine detects an anomaly automatically.

2. Alert Activation

The operator pulls a cord or presses a button (in traditional systems).
In modern systems, a wireless Andon device or sensor triggers the alert.

3. Signal Transmission

The Andon device lights up in a particular color (for example, red for critical, yellow for warning) to indicate the nature of the problem. An audio alarm may also go off.
Simultaneously, the Andon board/dashboard updates to show exactly which station or machine has raised an alert.
In some sophisticated setups (like Glansa's), SMS or email alerts are also sent when an Andon is raised.
Supervisors, maintenance staff, or quality teams are immediately notified and go to the affected workstation.
Depending on the severity, production might be paused so that the issue can be addressed.

4. Continuous Improvement

All Andon events (alerts) are logged for root-cause analysis, helping teams identify recurring bottlenecks. Over time, the data collected can inform Kaizen initiatives (continuous improvement), reducing waste and improving efficiency.

Why Use an Andon System?

There are several compelling advantages to implementing an Andon system:

Real-time visibility and communication: Alerts are immediate, helping detect issues the moment they occur and ensuring timely interventions.
Reduced downtime: By acting swiftly, teams prevent small problems from escalating into bigger issues that could stop production.
Improved quality: Operators can stop production at a defect, preventing faulty items from moving down the line.
Empowered employees: Workers have the autonomy to alert supervisors or halt lines, which encourages ownership and accountability.
Data-driven improvement: Logged Andon events help management analyze patterns, identify recurring root causes, and drive continuous improvement.
Safety enhancements: Audible and visual alarms can serve as safety alerts, ensuring hazards are addressed quickly.

Applications of the Andon System

Automotive manufacturing: The classic use case, where the Andon cord or button allows line operators to stop production to fix quality problems.
Pharmaceutical & medical device manufacturing: Due to stringent quality requirements, Andon systems help promptly flag deviations and enforce corrective action.
Electronics and assembly lines: Automated sensors and Andon dashboards provide real-time insights, making processes more responsive.
Modern "smart" factories: IoT-enabled Andon devices push alerts to mobile apps and cloud platforms for remote monitoring.

Glansa's Wireless Andon System

Glansa offers a wireless Andon system designed to bring lean manufacturing principles into modern, digitized production environments. Key highlights:

Wi-Fi connectivity: The Andon device connects to the local Wi-Fi network, and the system gives a signal status indicator for connection health.
Color-coded alerts: Glansa's Andon system uses at least two colors â€” red for critical issues, yellow for medium ones. If any Andon device is red, the main tower light shows red; otherwise, if only yellows are active, it shows yellow.
Intuitive issue reporting: Operators can raise alerts using a simple interface, choosing predefined fault descriptions, picking the type (color) of issue, and selecting the plant name (automatically populated).
SMS & Email alerts: When an Andon is raised, automated SMS and email notifications go out to relevant stakeholders so that action can be taken quickly.
Tower light indicators: The system has a tower light that changes color based on the most serious active Andon, which gives a quick visual cue to everyone on the shop floor.

Challenges & Best Practices

While Andon systems can dramatically improve visibility and control, successful implementation requires attention to a few challenges:

Overuse of alerts: If operators raise Andons too frequently for trivial problems, alert fatigue can set in. It's important to define clear rules about when to trigger an Andon.
Response discipline: Alerts are only useful if there's a structured, immediate response. Teams must have a clear process for triaging and resolving Andon signals.
Data analysis: Simply logging Andon events isn't enough. Regular reviews and root-cause analysis are necessary to convert insights into process improvements.
Scalability and integration: As the system scales, integrating Andon devices with MES (Manufacturing Execution Systems) or other factory software can be complex, but is vital for data coherence.
Training & culture: Operators and supervisors need to be trained not only to use the Andon device, but also to view it as a tool for continuous improvement, not just a "stop button."

Conclusion

The Andon system â€” andon device included â€” is more than just a warning light: it's a powerful enabler of real-time communication, quality control, and continuous improvement in manufacturing. Whether you're running traditional assembly lines or forward-looking smart factories, implementing a robust Andon system can drive down waste, minimize downtime, and foster a proactive, empowered workforce.

Glansa's wireless Andon solution, with its color-coded alerts, SMS/email notification, and Wi-Fi connectivity, shows how modern technology is reinventing this lean manufacturing classic â€” making Andon more accessible, responsive, and data-driven than ever.

Interested in implementing an Andon system for your manufacturing facility?

Contact Glansa Solutions to learn more about our wireless Andon system and how it can transform your production processes.

10:00 AM to 7:00 PM

+91 913 347 1515 / +91 837 399 9047