Since the early days of manufacturing and production, andon systems have been used as a way to improve communication within manufacturing operations. These systems allow workers and management to quickly and easily identify issues with the production process and then take corrective action.

In this blog post, we will discuss how andon systems have progressed over time, and how they can benefit your business. We will also provide tips on how you can get started with andon systems in your own workplace. 

What Are Andon Systems?                                                                                                

What exactly are andon systems? Andon systems are communication and visual management tools that help to improve information flow and coordination in the workplace. 

These systems can take many different forms, but typically involve some form of visual display (e.g. lights, screens, etc.) that provides information on the status of the production process. Andon systems can be used to track a variety of different production metrics, but the most common use is to monitor the status of individual machines or assembly line stations.

What Are The Benefits Of Andon Systems?

Andon Systems offer a variety of benefits for production facilities and businesses, but some of the most notable include:

• Increased Productivity and Less Downtime –  Andon systems can quickly notify  employees and managers if there is an issue on the production line. This increases visibility allows for your team to pinpoint why the production issue has occurred and how to resolve the issue and even develop future goals to eliminate this from happening again. 
• Enhances Quality-  With Andon systems you are able to monitor and track quality control. This can help address impeding quality or safety issues.  The system can also communicate when parts aren’t working as they should. 
• Increased Safety- This system is easy to use and very user-friendly.  A tool that has a better user experience helps eliminate safety concerns. 

How Have Systems Progressed Over Time?

Andon systems have come a long way since their inception, and today there are many different types and styles of andon systems available. The most common type of andon system is the centralized andon system, which uses a single display to provide information on the status of multiple machines or assembly line stations.

Another popular type of andon system is the distributed andon system, which uses a network of individual displays to provide information on the status of the production process.

Andon systems have also evolved in terms of the technology that they use. Early andon systems used simple lights or mechanical displays to provide information on the status of the production process. Today, many andon systems use LCD or LED screens to provide more detailed information on the production process. Andon systems also use email, text, and additional forms of communication to disperse pertinent information.  

Additionally, Andon systems have changed in terms of the way that they are used. In the past, andon systems were typically used to track the status of individual machines or assembly line stations. Today, many andon systems are also used to track more comprehensive production metrics such as cycle time, yield, and throughput.

How Can I Get Started With Better Manufacturing?

If you’re interested in implementing andon systems in your own workplace, there are a few things that you need to keep in mind. First and foremost, you need to identify the specific needs and objectives of your business. What are you hoping to accomplish with andon systems?

Once you have a clear understanding of your goals, you can begin to look for andon system suppliers that offer products that meet your specific needs. Implementing andon systems in your workplace can be a great way to improve communication and coordination, and ultimately improve your business. 

Want to learn more about how andon systems can help your manufacturing business? Reach out to an andon expert from VersaCall today. 

 

If you’re running a manufacturing business, then you know that quality and efficiency are key. You also know that there is always room for improvement. One way to improve your operations and achieve the best possible results is through andon system implementation.

In this blog post, we will discuss what andon systems are and how you can go about implementing them into your own manufacturing business.

What Are Andon Systems?

Andon systems are visual management tools that are used to communicate and track the status of production. They were originally used by Toyota in their production lines, but the concept is now used in a variety of manufacturing sub-industries. 

This communication method typically uses lights to indicate the status of production. They can be used to display information such as the current production status, target production rates, and quality control data.

These systems can also be used to trigger alarms in the event of a problem or issue. For example, a green light might indicate that everything is running smoothly, while a red light might indicate that there is a problem that needs to be addressed.

What Are The Benefits of Andon Systems?

There are many benefits to andon system implementation. Some of the most notable benefits include:

• Improved communication and collaboration: Andon systems make it easy for everyone in the organization to see and understand the current production status. This can help to improve communication and collaboration between different teams and departments.
• Better quality control: These systems make it easy to track production data and identify issues or problems. This can help you to maintain better quality control over your operations.
• Increased efficiency and productivity: Andon systems can help you to identify and resolve problems quickly. This can lead to increased efficiency and productivity in your operations.
• Reduced costs: They can also help you to avoid or reduce the cost of production issues and problems.
• Reduced downtime: Finally, andon systems assist with quickly identifying and resolving problems. This can lead to reduced downtime and increased production.

Andon System Implementation

Now that we’ve answered the question “what are andon systems?” It’s time to discuss how you can implement them into your own business.

There are a few different ways that andon systems can be implemented into your business. The most common way is to use andon boards. Andon boards are physical screens that display production information and data. They typically use colors to communicate the status of production.

Another way to implement andon systems is to use andon software. Andon software is a digital tool that allows you to communicate, track, and manage production data. It can be used to display information on andon boards, and it can be used as a reporting tool.

Whichever method you choose, there are a few key steps that you need to follow in order to successfully implement andon systems into your business.

Choose the right andon system for your business: There are a variety of andon systems on the market, so it’s important to choose the one that’s right for your business. Consider factors such as cost, features, compatibility, and a company’s experience before making your decision.

Train your employees: Andon systems can be complex, so it’s important to train your employees on how to use them. Make sure to provide clear and concise instructions on how to successfully utilize the system.

Monitor and adjust: Once you’ve implemented andon systems into your business, it’s important to monitor and adjust them on a regular basis. This will help you to ensure that they’re working effectively and efficiently.

Need Professional Help?

Andon systems can be a great addition to any manufacturing business. They can improve communication and collaboration, quality control, efficiency, and productivity. If you’re looking to implement andon systems into your business, reach out to lean manufacturing professionals at VersaCall today. 

In the manufacturing world, an Andon is a signal device that alerts operators or management to a problem. There are many different types of Andons, but all share the same purpose: to notify operators and first responders of a problem so they can take corrective action.

Here is an explanation of Andons, as well as six real-world examples of Andons and their uses.

What Is an Andon?

Andon systems are a type of visual management system. They consist of a series of lights or signals that allow operators to communicate problems to management. The name Andon is derived from the Japanese term “andon,” which means “lamp” or “light.”

The name “Andon” comes from the original Andon systems, which were llight-up boards that glowed when an andon cord was activated. Modern Andon systems employ the use of tower lights, screens, and additional methods of communications, to notify management and personnel of issues.

Examples of Andons

Here are six real-world examples of andons being used in different industries:

1. Toyota

Toyota is known for its well-run manufacturing plants. The Toyota Production System (TPS) uses a number of visual management tools, including andons.

The Andon system consists of every Toyota automobile having a portable indicator light on the production line, following it down the line. That indicator light has blue, green, and red lights. The light turns from blue to green when a mechanic tightens a bolt on a vehicle, and the automobile continues down the line.

However, if one of the bolts on a production line is excessively tightened or left untightened, the indicator light flashes red and the Andon board turns orange on that area of the manufacturing line. If the bolt is not addressed promptly, production will be halted and the team must congregate to quickly address the problem at that part of the manufacturing line.

2. Amazon

Andon systems help Amazon maintain their high standards of good packaging, quality service, and speedy deliveries. The Andon alerts at Amazon indicate a variety of issues on the production floor in real-time, meaning time isn’t wasted on fixing issues such as defects in inventory, reported product updates, etc.

Andon systems give workers and supervisors a chance to reduce wasted time and monitor each other’s progress and performance. Amazon’s massive workloads of packing and shipping products requires as little waste as possible, and Andons help accomplish this.

3. Honeywell Andons

One of Honeywell‘s locations consisted of 4 separate factory operations with one common support group. VersaCall helped Honeywell to implement an Andon system which reduced line downtime for the 4 separate factory operations.

The one support group had previous difficulty in identifying and fixing problems quickly. The Andon system helped the support group by providing them with immediate communication of where line stoppage issues were across the 4 separate factory operations.

4. 3M

At the 3M Tape Manufacturing Plant located in Minnesota, the facility was experiencing a significant loss of production time due to the response time of support personnel to unanticipated production disruptions. This plant implemented VersaCall’s VT3000, an Andon system which included 4 button calls that were within reach of every operator.

The press of a button sends communication immediately to a specific person or group who will need to address problems in that specific area. The Andon system helped provide an immediate response to issues.

5. Caterpillar Inc. Andons

Caterpillar Inc. has implemented the Caterpillar Production System to continue to improve their production processes by determining an effective way to communicate problems and issues from the assembly line on the production floor.

The Andon solution used was VersaCall’s 4 Button Wireless Call Station with stack lights at each work station on the production line with the ability to send communications to any location on the entire site. There is also display software for displaying the status of the entire production line as well as the status of each of individual work zones. 

Helping employees and management see the production status by individual production line and work zones was key in reducing downtime and response time.

6. Hamilton Sundstrand Andons

One operation of Hamilton Sundstrand consists of many assembly lines and groups, yet only one support group. Hamilton Sundstrand opted for an andon system that would help them identify the root cause of problems when they arise. 

VersaCall’s BSC Modules at each of the assembly stations provided for the immediate communication of multiple support requests. The modules captured the time and reason associated with each support request to provide the root cause of time loss on the floor.

Looking To Implement Andon Systems?

Each of these types of Andons can help manufacturers ensure that their operators and management are alerted to any potential problems so they can take corrective action.

If you’re looking for a way to improve your manufacturing process, consider using an Andon system. Contact VersaCall today to learn more about our Andon systems and how they can benefit your business.

In the manufacturing world, downtime is costly. Every minute a machine is not producing a product can mean lost revenue. In an effort to minimize this loss, many manufacturers have turned to Andons. 

Manufacturers in many different industries have found that Andon systems work efficiently in reducing manufacturing downtime. Here’s some more information about how Andons can help reduce costly manufacturing downtime.

What is Manufacturing Downtime?

Manufacturing downtime is the amount of time a machine or process is not running. This can be caused by a number of factors, such as equipment failure, material shortages, or operator error.

Downtime can have a significant impact on a company’s bottom line. In fact, it is often one of the most expensive aspects of manufacturing.

What are Andon Systems?

Andon systems are a type of visual management system. They consist of a series of lights or signals that allow operators to communicate problems to management.

The name Andon is derived from the Japanese term “andon,” which means “lamp” or “light.” The name “Andon” comes from the original Andon systems, which included light-up boards that glowed a specific color indicating any issue affecting production. The Andons cord was a physical action that workers could take to indicate that there was an issue in production, and they could also use it to stop production entirely if necessary.

Modern Andon systems employ the use of tower lights, screens, and additional methods of communications. An example of the meaning of visual signals on the floor is green for normal operations, yellow indicating that changes are called for, and red as an indicator that production has stopped.

While Andons can be used in any manufacturing setting, they are most commonly found in assembly plants and on production lines.

There are several benefits of using Andon systems, as they can

• Identify and address problems quickly
• Improve communication between operators and management
• Reduce and track manufacturing downtime
• Analyze downtime events to continuously improve 

How Can Andon Systems Reduce Manufacturing Downtime?

Andon systems are an effective way to minimize the cost of manufacturing downtime. They provide a way for operators to signal issues to management quickly and effectively. By identifying and addressing problems as they occur, companies can minimize the amount of downtime their machines experience. 

In addition, Andon systems can help improve communication between operators and management. This can help ensure that problems are addressed promptly and that everyone is aware of the status of the production line. When the problems are addressed promptly, the manufacturing downtime can be greatly reduced.

Want to Reduce Manufacturing Downtime?

If you’re looking for a way to reduce the amount of manufacturing downtime your company experiences, consider installing an Andon system. Andon systems provide the perfect way for operators to signal problems to management quickly and effectively. This can help identify and address problems quickly, minimizing the amount of downtime your machines experience.

For more information about Andon systems and how they can help reduce downtime, contact VersaCall today.