What Is Andon System And How To Use It?

What Is Andon System And How To Use It?

Andon is a Japanese word that is usually used in lean manufacturing. Andon means sign or signal in English and when used under the lean manufacturing approach, the Andon system refers to the system that notifies management, maintenance or other workers when there is a problem with the quality or with the process.

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The Andon system requires the use of an electronic advice that incorporates some kind of signal lights that alert whenever there is a problem. Some more advanced can also include audio alarms, text, or other forms of visual displays. ​

One of the things that you need to understand about the Andon system is that it is deeply connected to the Jidoka quality control method. In fact, it's not possible to understand the Andon system without understanding Jidoka first.
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One of the best examples of the Jidoka use that we can give you is related to the Toyota System Corporation. The truth is that the company was the first one to implement a system where the process was immediately stopped in case there was a suspect of a defect. According to the Jidoka principle, when the process stops, you have an immediate opportunity to improve the entire process. Jidoka is usually used in lean manufacturing to help you discover a problem as soon as it happens and to immediately develop solutions to prevent it from happening again. ​

So, what is the relationship between the Andon system and the Jidoka?

Simply put, the Andon system acts as the principal and as the typical tool at the same time that is applied to the Jidoka principal. Usually, in order to activate it you just need to pull a button or a cord and at this moment the team can all get together and apply the Plan-Do-Check-Act (PDCA) Cycle, apply the root-cause analysis, and, finally, apply the solution as quickly as possible.

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One of the things that you need to know about the Andon system is that it can work very well for a wide range of industries, In fact, we have been different organizations using this system for consumers. Just think about your car's dashboard. Whenever it detects that you have low oil or fuel. a light will appear on the dashboard so that you know what is happening immediately.

Using The Andon System In Manufacturing

Using the Andon System in manufacturing brings a lot of benefits. These include an increased level of uniform product quality, greater sales through global markets, a better design of products which also provides an improved service, and a higher level of product testing.

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In case you are looking to start using the Andon system within your organization, you need to understand that its use will completely eliminate the need for whiteboard, clipboards, and even word-of-mouth.

Since you will give the workers the power to pull the button and stop the process, they are usually told to do it when the following occurs: ​

• a defect is found or created
• there is a part shortage
• the existence of a safety problem
• a tool malfunction.​

As soon as the alert is given, the work will remain stopped until someone finds a solution.