Andon, a Lean tool, is a visual management tool that highlights the status of operations in an area at a single glance. Following this, it signals whenever an abnormality occurs. Therefore, it is needed to prevent bottlenecks.
Andon is a digital broadcast of information. The production personnel must take suitable actions when there is a deviation from the plan. If it does exist, then they should do a ‘why – why’ or root cause analysis. Following this, there needs to be an action implementation. However, you must keep in mind that Andon doesn’t solve problems. It aids problem-solving by providing necessary information at the point of use.
Uses of Andon
Here are some of the many uses of Andon:
- Firstly, an Andon is significant in terms of production status. For instance, it shows which machines are operating. Additionally, it indicates the number of units planned versus the actual output.
- Secondly, it plays an important role in identifying an abnormality. For example, it highlights machine downtime, quality problems, operator delays, and material shortages.
- Thirdly, an Andon is responsible for pointing out needed actions such as changeovers.
- Fourthly, this Lean tool ensures that a number lights when a problem is detected by a machine sensor. This automatically trips the appropriate light, or by an operator who pulls a cord or presses a button. Thereafter, the illuminated number summons a quick response from the team leader.
- Lastly, an Andon incorporates the usage of coloured lighting on top of machines to signal problems (red) or normal operations (green). This makes people aware of the problem areas.
Example of Andon board in a line