Presents

1

• Presents
• An introduction to Andon

2
Contents

• Andon Concept/Origins
• Types of Applications/Examples
• Andon Products Available

3
Andon Concept/Origins

• In ancient Japan Andon was a paper lantern that
  contained a candle inside.

4
Andon Concept/Origins

• These lanterns were used as a flashlight, for
  commercial signs and as a signaling light.
• In our time Andon is a term still used for
  signaling in the workplace.
• Andon is the term used for a visual and/or
  audible notification control tool (Jikoda)
• Andon is a visual control device that shows
  machine, line or process status. It is a very
  useful tool in lean manufacturing systems where
  the main goal is to reduce production waste in
  all levels.

5
Andon Concept/Origins

• The concept is that when operators have an issue
  they use the Andon system to signal for help
• Once activated support staff who can address the
  problem should quickly respond
• Andon systems vary greatly from the very basic to
  hi tech solutions

6
Andon Concept/Origins

• An Andon promotes visual factory and serves two
  goals. 
• First, it enables the production personnel to
  remain at their workstation when they have an
  issue. 
• Second, it reduces response time and more
  efficiently gets the support personnel to the
  line where they are needed to get the line back
  up and running.

7
Key Learning

• It needs to be well understood that the Andon
  system enables workers to stay at the line
  WORKING and signal the support staff to come to
  them. 
• Often companies may question spending money on a
  system to keep a 15/hr worker in place to signal
  a 50/hr engineer? 

8
Key Learning

• They need to look at it in terms of the value of
  their operation running versus not running. 
• If that 15/hr employee is not working, their
  value stream worth 50,000/hr is not running. 
• So the real question they need to answer is,
  whats their uptime worth?

9
Types of Applications

• An organisation may want to signal either the
  same respondent i.e. team leader for different
  issues or may wish to signal different
  respondents for different issues.
• Typically an Andon light system can be used for
  this type of application

10
Types of Applications

• An example of same respondent for different
  reasons

Red - Line stopped team leader required now
Amber - Line slowing or will stop shortly team
leader required ASAP
Green - Line running as desired no team leader
response required
11
Types of Applications

• An example of different respondents for different
  reasons

Red - Line stopped Team Leader required now
Amber Quality issue - QA staff required now
Green - Line running as desired no response
required
White Maintenance issue - Maintenance staff
required now
12
Types of Applications A Typical Example

• On the line if an operator has a problem he/she
  pulls the Andon cord to signal that help is
  needed
• Pulling this cord lights up an overhead light
  stack and sounds a tone that is specific to that
  particular area

13
Types of Applications A Typical Example
14
Types of Applications Typical Examples

• Individual Andon Light stacks might be linked to
  a central light stack that can be located in a
  more visible location
• Often the audible alarm is part of the central
  light stack so that it does not create any OHS
  issues

15
Types of Applications Typical Examples

• Typical installations can also be linked to a
  timer
• The timer can be used for many different reasons
• A common use is to manage TAKT times

16
Types of Applications Typical Examples

• The TAKT time (cycle time) can be entered i.e. 60
  mins. and the timer will count down
• If the counter gets to 0 and the work areas have
  completed their task and pressed the green button
  the timer will automatically reset
• If a red light is displayed when the timer
  reaches 0 it will not reset until the problem has
  been addressed and the light has been changed
  back to a green
• If a amber light is displayed when the timer
  reaches 0 it will change to red and follow the
  same process as above

17
Types of Applications Advanced Example

• A more advanced Andon system includes an Andon
  Board
• An Andon Board is a visual control device in a
  production area, typically a lighted overhead
  display or board.

18
Types of Applications Advanced Example

• Andon Boards can be computer screens, paper
  charts, electronic boards, manual boards, LCD
  screens.
• They often include lights and/or sounds to
  communicate the status of a process and to call
  for help.

19
Types of Applications Advanced Example

• Andon Boards are used to give the current status
  of the production system and alert team members
  to emerging problems or an abnormal situation
• Sometimes the Andon board can also indicate what
  type of help is needed (maintenance, team leader,
  supplier etc)

20
Types of Applications Advanced Example

• In a factory the Andon board needs to be located
  where it can be clearly seen (often in many
  locations)
• For remote locations the Andon board is usually
  on computer networked to everyone who needs to be
  aware of the status of the processes at that
  location

21
Andon Products Available
22
Andon Products Available
23
Andon Products Available