Modern manufacturing suffers when problems stay hidden. A missed defect can trigger scrap, delays, and rising costs within minutes. Andon in lean manufacturing solves this by giving your production line a clear, immediate signal when something goes wrong. It works as a visual management system that lets operators stop the line and raise alerts the moment an abnormality appears.
With andon in lean manufacturing, teams rely on real-time problem detection instead of guesswork. Lights, sounds, and screens push fast action, not delayed fixes. Plants using Andon see lower downtime, stronger operator ownership, and tighter quality control. This is how lean thinking stays practical on the factory floor.
What is the Andon System? The Basics
Andon in lean manufacturing is a shop floor signaling method that makes problems visible the moment they appear. It removes delay and guesswork from daily production decisions.
How it works:
- Green light means the line runs as planned
- Yellow light flags a warning that needs supervisor attention
- Red light stops production for immediate action
Why it matters:
- Andon in lean manufacturing works as a clear visual management system.
- Operators raise alerts without fear
- Teams get real-time problem detection at the exact station.
- Managers see issues instantly without walking the floor.
This setup strengthens production line communication, speeds response time, and keeps quality issues from moving downstream. The next step is seeing how Andon moved from manual cords to data-driven digital systems.
Evolution of Andon Systems
Andon did not stay the same as production lines grew faster and more automated. What started as a simple visual signal changed into a connected system built for speed, accuracy, and data.
1. Traditional Andon Systems
Early andon in lean manufacturing relied on manual pull cords, buttons, and stack lights. Operators raised a signal when a defect or machine issue appeared. Supervisors noticed the alert and walked to the station.
This approach supported basic visibility through a visual management system, but response time varied, and no data stayed recorded. Tracking Overall Equipment Effectiveness OEE or driving consistent downtime reduction in manufacturing remained difficult.
2. Digital Andon Systems
Modern andon in lean manufacturing uses sensors, connected devices, and dashboards for real-time problem detection. Alerts reach teams instantly, and every stoppage is logged with time and reason.
This strengthens factory floor communication, supports production efficiency monitoring, and gives teams clear insight into recurring issues.
Next, let’s break down how the Andon process actually works on the shop floor.
How the Andon Process Works
The andon in the lean manufacturing process follows a clear flow. Every step focuses on speed, clarity, and accountability on the shop floor.
Step 1: Detect the Issue
An operator spots a defect, abnormal sound, or process deviation. In advanced setups, sensors handle real-time problem detection automatically. This supports faster production line communication and prevents defects from moving forward.
Step 2: Trigger the Andon Signal
The operator pulls a cord or presses a button. In digital setups, the system triggers alerts on its own. Lights turn red, alarms sound, and dashboards update. This activates the visual management system instantly.
Step 3: Immediate Response
Supervisors, maintenance, or quality teams move straight to the affected station. This quick reaction reduces idle time and supports downtime reduction in manufacturing without waiting for escalation.
Step 4: Fix and Record
Teams correct the issue, restart production, and log the cause. This data feeds Overall Equipment Effectiveness (OEE), strengthens production efficiency monitoring, and supports long-term improvement.
This structured flow explains why Andon stays effective under real production pressure.
Implementation Roadmap for Andon Systems
Rolling out andon in lean manufacturing works best with a phased approach. Each phase builds trust, clarity, and speed on the shop floor.
Phase 1: Define Clear Triggers
Set simple rules for when to activate Andon. Focus on safety risks, quality defects, abnormal machine sounds, or process delays. Clear criteria remove hesitation and support operator empowerment with real-time problem detection.
Phase 2: Install Visual Signals
Deploy stack lights or screens at every station. This creates a reliable visual management system that everyone can see. Digital dashboards improve factory floor communication without adding confusion.
Phase 3: Train the Team
Explain why stopping the line protects output and quality. Reinforce that using andon in lean manufacturing leads to faster fixes, not blame. This step shapes a strong continuous improvement culture.
Phase 4: Use the Data
Review stoppage logs weekly. Track trends tied to Overall Equipment Effectiveness OEE and downtime reduction in manufacturing. Data turns daily alerts into lasting process fixes.
This roadmap keeps Andon practical from day one.
How Jidoka Tech Enhances Andon
Andon in lean manufacturing works best when problems get flagged without delay or human dependency. Jidoka Tech strengthens this by turning inspection into an automated trigger. Cameras, lighting, PLC timing, and edge units work together so issues surface across every shift.
- KOMPASS detects defects at 99.8%+ accuracy in under 10 ms, even on reflective or fast-moving parts.
- NAGARE tracks every assembly step and flags missing actions in real time. When an issue appears, the system triggers alerts instantly through the visual management system.
This setup delivers real-time problem detection, tighter production line communication, and stronger quality control without slowing the line.
Connect with Jidoka Tech to see how automated Andon brings faster response and tighter quality control to your production line.
Conclusion
Andon in lean manufacturing gives your production line a clear voice. It exposes problems the moment they appear and pushes teams to act fast. This approach replaces delay, guesswork, and repeated firefighting with visibility and discipline.
When alerts tie directly to data, teams improve Overall Equipment Effectiveness (OEE), reduce downtime, and protect quality at scale.
Jidoka Tech strengthens this model by automating detection through vision systems and connected alerts. Instead of waiting for human reaction, issues trigger signals instantly.
Connect with Jidoka Tech to see how automated Andon helps your team catch issues early and keep production on track.
FAQs
1. What does "andon" mean in Japanese?
Andon means "lantern" or "light" in Japanese. In andon in lean manufacturing, it refers to a visual management system that uses lights or screens to signal issues and support fast production line communication on the shop floor.
2. How does Andon improve OEE?
Andon in lean manufacturing improves Overall Equipment Effectiveness OEE by cutting response time. Faster real-time problem detection reduces idle time, limits defect spread, and supports better downtime reduction in manufacturing through quicker fixes.
3. Can Andon be automated?
Yes. Digital andon in lean manufacturing uses sensors, cameras, and automated alerts. This enables real-time problem detection, accurate stoppage logs, and stronger production efficiency monitoring without relying only on manual signals.
4. Is Andon limited to automotive manufacturing?
No. Andon in lean manufacturing is widely used in electronics, pharma, food, and packaging. Any industry needing fast alerts, clear factory floor communication, and consistent quality can benefit from an Andon system.
