Andon

(Process Control Board)

19 November 2023
Page 1
 Andon
What is Andon ?

Japanese translation: Lantern

• A visual control that enables the operator to inform the Team Leader
(or responsible line cover) that an abnormal condition exists.

Note: IT IS NOT A TOOL TO STOP THE LINE, IT IS

IN FACT A TOOL TO KEEP THE LINE RUNNING

Author: Dave Bate 19 November 2023

Vaillant Training, Belper Page 2
 Andon
Process Control Overview PLAN 153

12:05
LINE
LINE11 PROD 146

DOWN 021

1 2 3 4 5 6

Vehicle Flow
PRE HELP PST

EQUIP

QUALITY

SYSTEM HEALTHY

ONE TOUCH ONE TOUCH ONE TOUCH ONE TOUCH

FIRST TIME FIRST TIME FIRST TIME FIRST TIME
EVERY
10% 30%
TIME
50% 70% 90%
EVERY TIME EVERY TIME EVERY TIME

L10 L10 L10 L10

H A LEW O O D Yamazumi Board
Team: GLX1: GLX2: Last Update:

Yamazumi Key:
Work Classification Working Position
R1 R2 R3 R4
Value Added Work
C1 C2 C3 C4
Non-Value Added Work L1 L2 L3 L4

Essential NVAW
S1
Option Work
Icons
Associated Associated Quality
Variant Work ENVAW NVAW Critical

15%
85%
5%
Time – 1sec=5mm

40%

60%

35%

R e t r a c t o r LH Retr a cto r RH Ca r p e t Fi t Lo o m

Processes

Author: Dave Bate 19 November 2023

Vaillant Training, Belper Page 3
 Andon
• Is activated by :
• the process operator manually
• automatically by links to equipment
• Provides real time information.

• Trigger for problem solving.

• Prevents concerns being passed onto the next

process ie Supports JIDOKA

• Key driver towards Lean Manufacturing.

Author: Dave Bate 19 November 2023

Vaillant Training, Belper Page 4
 •PULL IF QUALITY OR SAFETY ISSUE
•PULL TO ALERT T/L OF ANY
ABNORMALITY
•STOP- CALL- WAIT

Author: Dave Bate 19 November 2023

Vaillant Training, Belper Page 5
 PROBLEM INDICATION RESPONSE
Author: Dave Bate 19 November 2023
Vaillant Training, Belper Page 6
 Andon
What does it look like ?
• Simple to read.

• Information easy to understand at a glance.

• Prominent location for the line support to see.

• Shows location of the concern, not detail.

PLAN 153 LINE 1 PROD 146
12:05 DOWN 021
1 2 3 4 5 6
PRE HELP PST

EQUIP
QUALITY
SYSTEM HEALTHY

Author: Dave Bate 19 November 2023

Vaillant Training, Belper Page 7
 Andon
PLAN 153 LINE
LINE 11 PROD 146

Hardware overview: 12:05

1 2 3 4 5 6
DOWN 021

PRE HELP PST

EQUIP
QUALITY

Pull cords and beacons

SYSTEM HEALTHY

Author: Dave Bate

Vaillant Training, Belper
 Andon

How does it work ? Line running

PLAN 153 LINE 1 PROD 146

12:05 DOWN 021

ATTEND 1 2 3 4 5 6
PRE HELP PST

CRD EQUIP
QUALITY P

SYSTEM HEALTHY

Author: Dave Bate

Vaillant Training, Belper
 Andon
How does it work ? Concern - Cord Pulled
Pull cords and beacons

PLAN 153 LINE

LINE 11 PROD 146

12:05 DOWN 021

1 2 3 4 5 6
PRE HELP PST
EQUIP
QUALITY
SYSTEM HEALTHY

Author: Dave Bate

Vaillant Training, Belper
 Andon
How does it work ? Relevant position
lights up

PLAN 153 LINE 1 PROD 146

12:05 DOWN 021

ATTEND 1 2 3 4 5 6
PRE HELP PST

CRD EQUIP
QUALITY P

SYSTEM HEALTHY
Author: Dave Bate
Vaillant Training, Belper
 Andon
Marquee PLAN 153

12:05
LINE
LINE 11 PROD 146

DOWN 021

1 2 3 4 5 6
PRE HELP PST
EQUIP
QUALITY
SYSTEM HEALTHY

The marquee shows the following information:

System healthy

Production Held Information

System fault Information

Emergency Stop information

Buffer warning levels

Maintenance Call Information

Author: Dave Bate
Vaillant Training, Belper
 Andon
Chimes

The purpose of the chimes is to alert the personnel in that area that
there has been a change in status on either the line side equipment or
on the local Andon board.
Every team on the line is allocated a sounder. Each sounder has the
ability to sound individual chimes.
Every line is usually allocated two chimes:
1st chime is for the purpose of warning the local team.
2nd chime is for the purpose warning the whole line.

Author: Dave Bate

Vaillant Training, Belper
 Andon
De-coupling and Managed Buffers.
Effective use of an Andon system relies upon the introduction
of de-coupled production lines with managed buffers.
De-coupled lines allow production areas to stop without
immediate effect to following and preceding areas.
It ensures that, within reason, a continuous flow of
production is maintained by using the managed buffers
between the lines.

Author: Dave Bate 19 November 2023

Vaillant Training, Belper Page 14
 Andon
De-coupling and Managed Buffers.

Total line stop

Stn 1 Stn1 - Stn 60 Stn 60

Line stop

Stn 1 Stn 20 Stn 41 Stn 60

Line stop
Line stop Managed buffers
Stn1-Stn20

Production continues
until preceding buffer
Stn 21 Stn 40
short

Author: Dave Bate 19 November 2023

Vaillant Training, Belper Page 15
 How big should the buffer be?

How to manage the buffer?

Set the buffer quantity based upon the line performance / downtime

Reduce buffers
as pulls &
downtime
reduce
No of
10 mins ~ 5 cars
pulls (depends on Takt)

1 2 3 5 10 20
Time in secs

Author: Dave Bate 19 November 2023

Vaillant Training, Belper Page 16