Introduction to Andon System
                     Andon System in Manufacturing: A Detailed Overview
Manufacturers today face significant challenges, from meeting customer 
demands to maintaining product quality and minimizing downtime. To 
overcome these challenges, many rely on the Andon system in manufacturing. 
This system is a vital component of Lean Manufacturing practices, emphasizing 
efficiency and quality.
What is an Andon System?
An Andon system is a visual and/or audible alert system used on 
manufacturing floors to identify and respond to issues in real-time. Its primary 
purpose is to ensure immediate communication between operators and 
supervisors whenever there’s a problem.
Originally introduced by Toyota as part of their Lean Manufacturing philosophy,
the Andon system allows workers to take corrective action immediately. This 
minimizes production delays and prevents quality defects from escalating.
Key features of an Andon system include:
 Real-Time Alerts: Problems are communicated instantly.
 Visual Signals: Lights or screens indicate the issue type and location.
 Audible Alarms: Sounds grab attention to ensure quick response.
 Operator Empowerment: Workers can stop production if necessary to 
address critical issues.
How an Andon System Works
An Andon system is designed to simplify problem identification and resolution. 
Here’s how it typically operates:
1. Problem Detection: A worker notices an issue, such as a defect in 
materials, machinery failure, or a supply shortage.
2. System Activation: The worker activates the Andon by pulling a cord, 
pressing a button, or using an automated sensor.
3. Signal Transmission: The system sends a visual or audible alert, often 
using color-coded lights (green, yellow, red) to indicate severity.
4. Notification: The alert notifies supervisors, maintenance teams, or 
relevant personnel.
5. Resolution: The issue is investigated and resolved promptly to minimize 
production delays.
What Are the Cords of Andon?
In traditional Andon systems, cords were physical pull ropes located near 
workstations. Operators would pull these cords to signal a problem. While 
cords remain symbolic of Andon’s history, modern systems have largely 
replaced them with advanced tools like:
 Push Buttons: Easily accessible and reliable.
 Wireless Devices: Flexible and portable, ideal for large-scale operations.
 IoT Sensors: Automatically detect anomalies and activate alerts.
Andon System Benefits in Manufacturing
The Andon system provides numerous benefits that significantly impact 
manufacturing operations. Here’s a closer look at its key advantages:
1. Enhanced Communication:
The system bridges communication gaps between workers, supervisors, 
and other departments. Alerts ensure everyone is aware of issues in real-
time, facilitating swift collaboration.
2. Reduced Downtime:
Identifying and addressing problems early prevents production lines 
from coming to a complete halt. This reduces costly delays and keeps 
workflows smooth.
3. Improved Quality Control:
By catching defects early, manufacturers can avoid passing defective 
products to subsequent stages of production, ensuring high-quality 
output.
4. Employee Empowerment:
Workers are given the authority to signal problems without fear of 
repercussions. This fosters a culture of accountability and trust.
5. Actionable Data Insights:
Modern Andon systems collect data on frequent issues, providing 
valuable insights for continuous process improvements.
6. Increased Customer Satisfaction:
With fewer defects and more efficient production, manufacturers can 
consistently deliver high-quality products, enhancing customer trust and 
loyalty.
How to Use Andon in Manufacturing
To maximize the benefits of an Andon system, manufacturers should adopt the 
following practices:
1. Train Your Team:
Ensure all employees understand how to use the Andon system, 
including when to trigger alerts and how to respond to them.
2. Standardize Alert Signals:
Use a consistent system of visual and audible signals to represent 
different types of issues (e.g., red for urgent, yellow for caution).
3. Encourage Proactive Reporting:
Create a workplace culture where employees feel confident in reporting 
problems without fear of blame or punishment.
4. Integrate with Other Systems:
Link the Andon system to broader production management tools for 
enhanced visibility and analysis.
5. Review and Analyse Data:
Use the data collected by the Andon system to identify recurring issues, 
evaluate root causes, and implement targeted improvements.
6. Conduct Regular Maintenance:
Keep the Andon system itself in optimal condition to ensure reliability.
How Andon Improves Production Quality
The Andon system directly impacts production quality by ensuring problems 
are identified and resolved promptly. Here’s how:
 Prevention of Defects: Operators can halt production at the first sign of 
an issue, preventing defective products from progressing further in the 
manufacturing line.
 Faster Issue Resolution: Real-time alerts lead to quicker response times, 
minimizing the impact of errors.
 Root Cause Analysis: The system’s data helps teams understand and 
eliminate recurring quality issues.
 Continuous Improvement: Insights gained from Andon systems drive 
long-term improvements in processes and quality standards.
Conclusion
The Andon system in manufacturing is more than just a tool—it’s a strategic 
approach to maintaining high standards of efficiency and quality. By 
empowering workers, streamlining communication, and enabling real-time 
problem-solving, the Andon system plays a crucial role in modern 
manufacturing environments.
Whether you’re dealing with a small-scale operation or a large production line, 
implementing an Andon system can help you:
 Improve production quality.
 Reduce downtime.
 Foster a collaborative and empowered workforce.