Andon is a term of Japanese origin and literally means indicator lamp or illuminated sign. Andon, a Lean Manufacturing technique, is used as an error prevention system in production processes. The purpose of the system is to inform operators or stop work through warnings when there is a product defect. The most basic feature of this system, which originates from the Toyota Production System (TPS), is a button or warning mechanisms placed on the production line. In this blog post, we will discuss the types of Andon, its benefits and more. What is Andon? Andon systems are audible or light warning systems that notify operators of a problem that occurs at a stage on the assembly line or in the production area. The system alerts operators when a machine stops, there is a delay in material supply or there is a quality problem. Andon is a technique used to detect problems like the Jidoko system. The main difference with Jidoka is that it aims to intervene by visualising the situation rather than stopping production. How does Andon work? Andon sends notifications to operators in case of machine stoppage, delay in material supply or quality related problems. It generally appears as user code and error code on LED-Matrix boards. With the widespread use of LCD and plasma televisions, modern screens are used instead of LED-Matrix panels. The error is announced to the operators with an audible warning system. Reporting is done through computer software. What are the Types of Andon System? Andon has two types, manual and automatic. Manual Andon / Andon Rope In the manual Andon system, there is a rope/rope located above the assembly line. If there is a problem, the andon rope is pulled and gives a signal that a problem has occurred. Andon ropes are placed at each operational station. In this way, it is quick for the operators to find the problem station. The triggered signal appears as user code and error code on the LED-Matrix panels on the machine. As a result of this warning, everyone stops working until the problem is eliminated. The technicians gather around the faulty station and find a solution. After the problem is solved, the andon is pulled a second time and allows the line to continue. Automatic Andon In this andon type, there is a system that automatically detects a problem occurring at a station. The difference from Manual Andon is that there is no human effort to alert the system. Inputs to the dashboard go automatically. It also sends SMS and digital notifications to team leaders or relevant departments. Basic Elements of Toyota Andon System The Andon system is based on four basic elements. Andon Indicators Green, yellow and red coloured lights on the production line indicate the status. Green light indicates that the operation is progressing normally and there is no problem. Yellow light indicates that a problem has been detected and will turn into a major problem if not intervened. Red light is the signal that informs everyone that there is a problem with production. Warning Buttons When operators encounter a problem at their workstations, they report the problem to the relevant people by pressing the warning buttons. Visual Communication In the Andon system, the station with the problem is visually communicated through boards or large screens. These boards enable the relevant people to quickly go to the station where the problem is located and produce solutions. Audio Warnings Andon systems can be combined with audible warnings where light indicators are not sufficient. An Example of an Andon Application Automotive Assembly Line: In an automotive manufacturing plant, the Andon System is used to improve quality and efficiency on the assembly line. A worker on the assembly line notices a mismatch or error during the assembly of a vehicle door. In this case, the worker activates the Andon System by pressing a button. This system switches on a light sign or indicator lamp at a specific point on the line and sends a warning signal. Steps: Reporting the Fault: The worker presses the Andon button when he notices a problem. Visual and Auditory Warning: The Andon System gives a light or audible warning, pointing to the relevant area on the assembly line. Stopping or Slowing Down Production: If necessary, the assembly line is automatically slowed down or stopped. This prevents faulty products from travelling down the production line. Troubleshooting: After the fault is reported, the quality control or maintenance team quickly identifies and fixes the problem. Production Resumes: Once the problem is resolved, the Andon System is reset and the assembly line continues to run at normal speed. Benefits of Andon in Lean Manufacturing Using the Andon system provides many benefits in the short and long term. 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