Andon is a visual and audible signaling system used on production lines to indicate the operational status of a cell, machine, or process. It is an essential part of the Lean Manufacturing philosophy, promoting operational transparency, immediate problem resolution, and standardization of failure response.
Andon transforms invisible problems into visible opportunities for action and improvement.
🔦 What is the purpose of the Andon system?
The main objective of Andon is to enable operators, supervisors, and maintenance or quality teams to quickly identify abnormal situations in production, such as:
- Lack of components or raw materials
- Machine stopped or in alarm
- Defect detected by the operator or automatic system
- Delays in the production cycle
- Accumulation of scrap or rework
🎯 Benefits of using Andon
| Benefit | Direct result in operation |
|---|---|
| Immediate visibility of failures | Speeds up response time |
| Team engagement | Operator actively participates in production control |
| Reduction of unplanned stops | Faster and more effective interventions |
| Support for real-time decisions | Supervisors have accurate and updated information |
| Basis for continuous improvement | Historical data feeds analyses and Kaizens |
⚙️ How does an Andon system work?
- Manual activation (physical button or touchscreen interface) or automatic (via PLC, sensor, or MES system)
- Visual signaling (light tower, LED screens, TV with dashboard) and/or audible
- Display of status such as: normal production, alert, failure, waiting, need for supervisor
- Integration with production systems: MES, ERP, SCADA or IIoT
🧩 Examples of colors in Andon towers
| Color | Typical meaning |
|---|---|
| Green | Normal production |
| Yellow | Attention / minor stop |
| Red | Failure / machine stopped |
| Blue | Request for technician or supervisor |
| White | End of shift or operation completed |
🔧 How AJOLLY Testing implements Andon solutions
AJOLLY Testing develops and integrates customized Andon systems for industrial environments that require efficient visual control, traceability, and quick response:
- Andon panels with live dashboard, audible and visual alarms
- Integration with testing systems, MES, database and Power BI
- Automatic collection of downtime, failure cause, and responsible operator
- Communication with testing equipment, PLCs, and line sensors
With AJOLLY Testing, Andon is not just an alert signal — it’s an intelligent tool for control, response, and continuous improvement.