Despite your best efforts, machines can malfunction without notice. In such cases, the faster you can alert operators about the problem and address it, the lower its impact on overall quality. This is where andon lights come in.
In terms of lean manufacturing, andon lights are part of a system to ensure problems in a manufacturing setup are quickly recognized and resolved to keep them from recurring. This article discusses the role of andon lights as an important lean manufacturing tool, its benefits, and the best way to implement it in your factory.
What Are Andon Lights?
Andon lights are part of the andon alarm system.
The lights themselves usually take the form of a column of red, orange, and green lights. The illuminated color signals the workstation’s operating status. A simple version would be:
- Red: The machine is facing a critical problem that requires urgent attention
- Orange: There’s a minor fault that requires assistance
- Green: Production is flowing smoothly
These stack lights can be customized or aligned with audio cues to attract additional attention.
Traditionally, machine operators pulled a cord to activate the andon lights when they noticed a problem. Today, buttons have replaced the cord. In many cases, the lights are also integrated with sensors to automate the system.
Origins of the Andon System
The evolution of the andon system goes back to the late 1800s and Sakichi Toyoda’s innovation of the power looms. These looms were designed to automatically shut down whenever a weft thread broke.
Later, when the Toyota Production System was being designed, this loom design inspired andon lights as a manual form of Jidoka or autonomation. Here, floor operators can stop production when they perceive an anomaly or potential threat to output quality. ‘Andon’ is a loose translation of a Japanese term for traditional paper lanterns.
Benefits of Andon Lights in Manufacturing
Lean manufacturing focuses on eliminating breaks to improve efficiency and reduce waste. In light of this, choosing to halt production may seem counterintuitive. To understand the benefits of andon lights, you need a shift in perspective.
If production were not halted, you would need to implement a temporary, makeshift solution. This may solve the issue at the time but will do little to prevent it from recurring. Halting production may disrupt the workflow temporarily. But, it allows operators and experts to find a permanent solution to the issue. This provides several long-term benefits:
Lowers Costs
Detecting quality issues early and halting production minimizes waste and the cost associated with it. Similarly, in the case of a breakdown, andon lights immediately alert floor managers about the problem. This form of early detection makes repairs easier and less expensive than if the issue were allowed to snowball into something bigger.
Improves Efficiency
Halting production through andon lights may temporarily pause production but in the long run, it reduces machine downtime. By ensuring that all problems, however small, are addressed in their early stages, it prevents recurrence and helps maintain a sustained production rate.
Simultaneously, it makes quality control easier and reduces the overall defect rate. Thus, factories are able to meet customer expectations and deliver orders on time.
Builds Transparency in Systems
Andon lights are a simple way for machine operators to communicate issues without waiting for supervisors. The system gives workers no incentive to hide issues but encourages them to react quickly. This keeps problems from slipping through the cracks and builds a culture of openness and transparency.
Empowers the Workforce
The andon system gives machine operators the power to make decisions without always having to wait for leadership. It decentralizes decision-making and helps the workforce feel more empowered. In turn, this increases engagement and drives employees to take ownership of their workstations and roles in the overall workflow.
Modern Digital Solutions of Andon Lights
While the key elements of andon Lights have stayed constant, the systems have evolved with technology to improve real-time monitoring of manufacturing processes.
Modern, digital systems supplement the traditional visual cues offered by andon lights with real-time data analytics. This gives workers a clearer understanding of where the problem lies and helps them understand the root cause of the issue. In turn, this leads to quicker problem-solving and higher efficiency.
Andon lights can also be integrated with digital visual management solutions in the factory for better communication. These systems push real-time notifications to all relevant stakeholders no matter where they are. This allows workers to collaborate with experts such as maintenance engineers even if they are not on the same physical shopfloor.
Customization becomes easier too. For example, in addition to the red, green, and orange lights, some factories also use a blue light to indicate that a machine has been stopped for routine maintenance and not because of an operational problem. Digital solutions for andon lights can also be set up to automatically escalate issues and delegate resolutions to teams based on their availability, skillset, location, etc.
Digitizing andon systems also supports data management and helps build institutional knowledge banks. For example, when a machine breaks down, the andon system not only alerts relevant parties but also logs the alert in the system. Engineers can later assess these alerts to spot patterns in machine productivity and evaluate the need for additional preventative maintenance or part replacement.
Tips to Implement an Andon System in Your Factory
Andon systems are often available as off-the-shelf solutions. You can customize them for your shopfloor. However, a good system alone does not guarantee success. Here are a few tips that can help.
Standardize circumstances for alerts
Andon lights empower employees to make decisions on when a production line must be halted and when it can be allowed to continue. But first, you must train employees to understand:
- What kind of output and production rate is accepted as ‘normal operation’
- When to call for assistance
- How to recognize anomalies and when to stop the line
Set a maximum shutdown time limit
The andon system focuses on finding permanent solutions to prevent a problem from recurring. However, this solution must be found quickly or it can disrupt the overall workflow and may affect your delivery timelines. Hence, define a timeline within which the team must find a solution or escalate the issue to a higher level.
Get all employees to adopt the system
For andon Lights to be effective, employees at all levels must trust and use the system. For example, even in the case of automated andon systems, operators must proactively observe the production line and take action whenever they deem fit. At the supervisor level, employees must recognize the importance of rapid responses. Similarly, managers must ensure their supervisors and operators are adequately trained and must be ready to step in quickly if help is required.
Getting Started with Andon Lights in Your Factory
Whether you’re manufacturing shoes or automotive parts, andon lights are a helpful tool. Integrating them with digital visual management systems such as fabriq can further enhance their benefits. This not only ensures that relevant stakeholders are notified of andon alerts but also logs the issues for overall maintenance checks.
Want to know more? Reach out for a demo of fabriq today.
