INDUSTRIAL

ANDON SYSTEM
Prepared by
OVERVIEW
• Andon is the Japanese term for a signaling system within a production
process or plant.
• Andon systems is a communication tool to communicate the status of a
production line or process to all production employees on the
production floor.
• The term "Andon" is used to refer to a visual system designed to notify
management, maintenance, or other workers of a quality or process
problem.
• In essence an effective Andon System will quickly identify to the
necessary stakeholders the location and nature of the problem.
• Leading companies around the world have successfully implemented
 OVERVIEW
• Andon system is able to share the information of your production line
among the operators & supervisors work in the lines at real time by
various display boards.
• Andon systems collect transform data into valuable information &
knowledge.
…EVOLUTION OF ANDON SYSTEMS
• Toyota created the Andon concept as a tool
for assembly line operators to notify other
workers and supervisors of an immediate
production issue. When a defect was
spotted or created, an operator would pull
an overhead cord to stop the assembly line
and trigger a light or sound.
• This would signal over someone to help
resolve the problem. The term Jidoka
“building quality in” motivated Toyota to go
through such lengths for quality assurance.
JIDOKA, BUILDING QUALITY INTO
ANDON
• Other companies have modified and
added to the Andon concept to expand its
relevance beyond the automotive sector.
• Companies have developed systems that
allow operators to send signals specific to
certain malfunctions. They have also
enhanced visual displays to communicate
to other operators and supervisors what
and where the problem is.
 INTERRUPT-DRIVEN DIGITAL SIGNAGE
FOR RAPID ISSUE RESPONSE
Andon Message Center
Open Andon tickets displayed by priority, color coded by
status.
Status fields include:
•Andon type
•Priority
•Work area
•Production
•Help type needed
•Resource type needed
Andon tickets can be raised, viewed, and updated, all with
just a few taps on the screen. Data can be viewed by line,
area or plant, and is accessible from desktop computers,
tablets or smart phones. Easy custom configuration for
Andon Reporting Center
Out of the box Analytics for:
•Open/closed tickets
•Open ticket duration trends
•Average Resolution Time
•Andon Issues Pareto chart
We can program custom analytics for your specific needs. Date range
reporting includes, YTD, MTD, WTD, today, previous week, previous
month.
Andon Broadcast Center
Andon system integrated with (MES) applications
Visible alert system can keep workers and managers in the know,
letting them fix issues quickly. The next-gen Andon can be integrated
with systems such as Epicor Manufacturing Execution Systems (MES).
The factory media center can also be linked with your EMI system so
production can be seen in real-time by your everyone on the floor.

Features:
•Distribute status on overhead TVs to display alerts on the factory
floor
•Provide real-time responsiveness to issues
•Configured to display for a single line, multiples lines, or a
ANDON LIGHTS INTEGRATION
Using our API, connect existing lights
with digital Andon software to get the
best of both worlds.

Lights alert work floor when issues arise,

while the next gen platform sends alerts
to operators, engineers, via digital
signage and SMS alerts—all while
gathering analytics to help improve OEE
over time.
INTELLIGENT MESSAGING
EXAMPLE
HOW TO USE AN ANDON – AND
HOW NOT TO
Quick Recap
An Andon is a system to aid the
information flow regarding the status of
the production system. Operators pull a
cord or press a switch if there are
upcoming or actual problems.

Similarly, machines and processes can

send a signal if something is wrong. This
information is then shown through lights,
numbers, and sounds to alert others
about the problems.
SIMPLE ARCHITECTURE
BENEFITS OF ANDON

• Significant time savings

• Cost reduction
• Better communication:
• Better control:
• Information collection
 NEXT-GEN ANDON :

Integrate with Andon lights to move from

static boards to a real-time alerts

• Cloud-based Andon Software that integrates with existing

systems
• Mobile connectivity Andon system.
• On- time Andon system
PLANT INFORMATION SYSTEM
• Be monitoring OEE
• Be monitoring tasks and cycle time
• Be upgrading Andon system lamps with USEFUL downtime alerts not just
flashing lights.
• Be monitoring your total output.
• Be monitoring your 3 losses to OEE- availabililty, Quality and
performance.
PLANT INFORMATION SYSTEM
APPLICATION SEGMENT OF ANDON
DE-COUPLING AND MANAGED BUFFERS
• Effective use of an Andon syatem relies upon the introduction of de
coupledproduction lines with manged buffers. De-coupled lines allows
production areas to stop without immidiate effect of following and
processing area. It ensures that, within reaosn a continous flow of
production is maintatined bu using the manged buffers between the lines.
HOW TO MANAGE BUFFER?
COMPUTER APPLICATION OF ANDON SYSTEM
ITEMS REQUIRED FOR USING DB (DATABASE)
MODE
• ANDON DB (database) serve
• MES Interface function license
• DB Connection Service
• DB Connection Service Setting Tool
• Cannot be used with GT2505 or GT25 handy models
• 1 license is required for 1 GOT unit
• DB Connection Service and DB Connection Service Setting Tool can be
installed from MES DB Connection Service (for GT Works3) that is
included in HMI/GOT Screen Design Software MELSOFT GT Works
OPERATING ENVIRONMENT OF ANDON DB
(DATABASE) SERVER
 DESIGN OF A METRONOME BASED ON THE
•
IDEA OF "ANDON
The whole system includes the position metronome, the production line LED screen and the
master control system. The metronome station as shown in Figure 1, each station has one, placed
in the middle of the site next to the station, the metronome has an LED countdown screen, rescue
button (with reset function), completion button, the button with operation status indicator, the
specification is 20cm * 20cm, and a red yellow green warning light is added above. Each station
has a walkie-talkie, in order to communicate between station and dispatcher directly .The
production line LED screen is shown in Figure 2, each production line has one, the specification is
200cm * 300cm, hang above the production line passage, the change of the background color on
each screen of the LED screen is consistent with that of the corresponding station warning light,
the existing emergency stop button is placed in the near of metronome. The master control
system is composed of computer and PLC control cabinet, the master control system controls
the operation of the plate chain, the computer records each button on each metronome and the
corresponding operation time. Administrators according to the requirements, set up tact time in
production line control equipment, after execution the implementation, the tact time displayed
on the metronome, metronome both the rescue and completion buttons are green. At the
beginning of production, employees start operation, at the same time the metronome countdown,
the completion button is red light. After the station finishing its operation need to click the
completion button for completion, after the countdown stopping, the finish button changes from
the red light to the green light. The system will ring out the route remind music when the beat is
left 2 minutes .When the system is finished that the beat has been set , if each workstations are
reported to be completed, then the system automatically routing (advance 10S will sound the
route warning music),if there is a workstation not reported completed, the production line
cannot route, the system records the number of stations that affect the line, and ring out the
music, after the abnormal station is completed, the system routing.
CONCLUSION

• The design scheme is based on ANDON system as the foundation,

combines with the design of the actual working conditions of the scene,
has high feasibility, through a clear station beat, enhances the
production line’s abnormal response ability, eliminates the unstable
factors of manual routing, establishes a rapid and transparent mode
of production management, the data of the system is recorded
comprehensively, and easy to formulate the corresponding
management standards, it is the effective tool to control the abnormal
burst. The system can improve the production efficiency of enterprises
effectively, and make production information more visual.
Thank You.....