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TBM Consulting Group

Operational Excellence One Point Lesson

Abnormality Management
Andon Lights Indicate Performance Issues
Category: Abnormality Management │ Business: General Application │ Lesson: 25 │ Author: Glenn Kubisiak

PROBLEM OR OPPORTUNITY
Supervisors and managers walking the shop floor cannot quickly determine if production is
staying within its daily scrap rate objectives.

COUNTERMEASURE
Supervisors and managers walking the shop floor cannot quickly determine if production is staying
within its daily scrap rate objectives.
● If the light is green, scrap is <2%
● If the light is yellow, scrap is between 2.1% and 4%
● If the light is red, scrap is > 4.1%

Andon Lights
RESULTS
A simple, cost effective method to enable a quick identification and response to a
problem on a production line.
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