Implementing a new system in a manufacturing facility is a decision that usually takes time to develop. Sometimes it stems from fatigue caused by repetitive, manual tasks that eventually start to cost too much time and energy. Sometimes it comes from observation, because even though the processes are working and people know what to do, more and more team members are beginning to notice that things could work better.
For example, an operator calls for the tenth time this week with the same report. The shift supervisor manually transcribes the data into a report after every shift. A maintenance technician learns about a breakdown late because someone forgot to call. Each of these activities individually seems like a minor task, but together they add up to a real cost in time and energy that the organization pays every day, often without even realizing it.
Or to put it another way: the processes are working, people know what to do, and the methods developed over the years keep production on track. However, one manager notices that reporting could be faster, then another points out that notifications arrive too late, and a third starts calculating how much time his team spends on tasks that the system could handle automatically. No one officially complains, because that’s just how it’s always been.
But “it works” and “it works well” are two different things. AndonCloud is a tool for those looking for their first system, because repetitive, manual tasks are starting to put a real strain on people and processes. And for those who have their own methods and are just beginning to ask themselves if it’s time to see what could be done better.
What situations could negatively impact the implementation of an Andon system?
Before we get into the plan itself, it’s worth stating clearly what most often causes system implementations on the production floor to fail. It’s not about the technology, because that rarely fails these days. It comes down to three things that recur in nearly every organization, regardless of industry or plant size.
- First, there is no one in charge of the implementation process. Someone made the decision to purchase the system, but no one in particular feels responsible for configuring and launching it. So the project gets passed around between departments.
- Second, the attempt to implement everything at once. Sometimes companies want to configure all lines, all statuses, all reports, and all integrations right away. The result is that instead of helping, the new system paralyzes work.
- Third, the lack of a trial period under real-world conditions. The system looks great in a demo, but no one has tested how it behaves during a specific shift, with specific operators, and during specific outages. It’s only after the purchase that it turns out something is missing.
A well-designed Andon system implementation process eliminates these risks.
5 steps to implementing AndonCloud. From the initial consultation to full-scale production.
Step 1. Interview. Tell us about your production
The first step is a conversation. Not a contact form that gets lost in your inbox, and not a downloadable brochure. It’s a brief meeting during which the AndonCloud team works to understand how your production operates. This isn’t a sales pitch in the traditional sense. It’s a diagnostic assessment.
The questions that arise at this stage typically concern the number of workstations and production lines, the types of products manufactured, common causes of downtime, current methods of status reporting, shift structure, roles and permissions within the system, and expectations regarding notifications.
The more you know about your issues, the better you can articulate your expectations. It’s equally important to identify what’s working well and what you don’t want to disrupt. A well-designed system takes both of these points into account.
Step 2. System demo. A presentation tailored to your needs.
Only after the conversation is it time for the demo. Not a general presentation of all features one by one, but a demonstration of the system components that address the issues you discussed in the first step. You can see how the workstation status update works, what the SMS and email notifications look like, how the system reports OEE at the end of a shift, and how to configure alerts for specific critical situations. If a feature doesn’t quite meet your company’s needs, it’s worth pointing that out right away. At every stage of the presentation, there’s time for questions and clarifying requirements.
Step 3. Trial period. 14 days of actual work with the system, not training in a conference room
This is where the actual implementation begins. For 14 days, you’ll have access to the full version of the system, and the AndonCloud team will assist you with the setup. This isn’t a demo version with limited functionality. It’s a production environment where you can configure real workstations, statuses, and notifications. System configuration is a step-by-step process. Each step is described in dedicated instructions that guide you through the entire process in a logical order. You don’t need to know everything from the start. Just begin with the first step, and the rest will follow naturally.
Throughout the entire trial period, the AndonCloud team is available to answer questions, assist with configuring workstations, statuses, notifications, and alerts, and address any issues that arise. The trial is a time when you can comfortably test how AndonCloud works in your environment, with full support and no pressure. What does the technical setup look like? AndonCloud operates in the cloud, so it doesn’t require installing servers, your own IT infrastructure, or advanced hardware. The hardware requirements are minimal: all you need is a computer with a dual-core processor, 8 GB of RAM, and the Google Chrome browser. It also works on tablets running Android or iPadOS. The system communicates via the standard port 443 (HTTPS), which means you only need to open a single port on your company network.
Step 4. Testing. You check how the system works in your environment.
The 14-day trial period is also a time for testing. It’s not just about clicking around the interface, but about verifying the system under real production conditions. You should pay particular attention to:
Are operators able to use the system effectively? AndonCloud is designed so that an employee at a workstation can easily change the status. A double confirmation of the status change prevents accidental calls, and the standard Andon colors—green, yellow, and red—are intuitive to anyone who has ever used a traffic light system. However, if it turns out that operators need training, the team can organize it.
Do notifications reach the right people at the right time? Here, it’s worth testing various scenarios: a breakdown in the middle of the night, a breakdown during a shift, or an escalation to a manager after a time threshold is exceeded. AndonCloud allows for 24/7 notifications or notifications only during working hours.
Do the reports show what you actually need? It’s worth reviewing the OEE reports, the reports on good and bad parts, and the real-time view on the dashboard. KPIs visible in real time give the manager an answer to the question of what’s happening on the shop floor, without having to call the shift supervisor.
Step 5. Decision. If the system meets your expectations, we’ll begin the actual implementation.
The final step is making a decision. If the system has been operating as expected for 14 days and you have data to back that up, implementation is the natural next step. It’s not a decision made in the dark. At this stage, the scope of the production launch is determined: which workstations and lines will be the first to go live, what user roles and permissions will look like, who will be the system administrator, and how shift schedules and periodic reports will be configured. A phased implementation—line by line or hall by hall—is an approach that works better than launching everything at once. It allows time for learning, configuration adjustments, and for the team to become familiar with the new tool.
What to Look for During Implementation? Practical Tips for Production Managers.
No matter how good the system is, implementation always depends on people. There are a few things worth establishing before you begin.
- Designate one person to be responsible for configuration and launch. This could be the production manager, a shift supervisor, or a continuous improvement specialist. It’s important that a specific person feels a sense of ownership over the project.
- Define a list of statuses before starting the configuration. Which situations are truly worth monitoring? Machine breakdown, material shortage, quality issue, planned downtime, tool change. The list should reflect what actually stops or slows down production.
- Determine who should receive which notifications. Not every piece of information is relevant to everyone. A shift supervisor needs a different scope of information than an operations director. AndonCloud allows for precise configuration at the role and permission level, which eliminates excessive notifications.
- Collect data as early as the first week of the trial. Even if the configuration isn’t perfect yet, the initial data from counters and statuses provides invaluable insight into where time is actually being wasted.
When you make a decision, you don't start from scratch.
After completing the five steps—the initial consultation, demo, trial, testing, and decision—you don’t have to start the implementation from scratch. You already have workstations set up, and statuses and notifications that have been tested and work in your environment. You know which production lines will be the first to go live and who on the team is responsible for the system. AndonCloud runs in a browser, with no installation, no servers, and no burden on the IT department. Data is protected by an SSL certificate, replicated, and backed up daily; the system runs while you work, including at night and on weekends. And if something goes wrong, technical support is available 24/7. In other words: when you decide to implement it, you already know exactly what you’re getting into. And you have the data to back it up.
FAQ
1. How long does it take to implement the Andon system? Basic configuration can take a few business days. Full production implementation, including multiple workstations, automation, and reporting integrations, depends on the size of the facility and the complexity of the processes. The trial period lasts 14 days and is often sufficient to evaluate the system under real-world conditions. Full production implementation typically takes place in stages, line by line, allowing for learning without the risk of disrupting the entire production floor.
2. Does implementing the Andon system require an in-house IT department? No. AndonCloud operates in the cloud and does not require the installation of servers or in-house IT infrastructure. All you need is a computer or tablet with a web browser and internet access via the standard port 443. Hardware requirements include a dual-core processor, 8 GB of RAM, and the latest version of Google Chrome. System configuration is done via the browser and is supported by the AndonCloud team throughout the entire trial period.
3. Can I test the system before deciding to purchase it? Yes. AndonCloud offers a 14-day free trial with access to the system’s full functionality. During this time, you can set up real workstations, test notifications, review reports, and see how the system works with your team in your specific environment.
4. Where should you start when configuring the Andon system? The configuration should be carried out in stages. First, define the status dictionaries; then create specific statuses, configure workstations, and finally set up counters for good parts and defects. This order follows the logic of the system. Each element depends on the previous one. Before starting, it is a good idea to define a list of situations that are truly worth monitoring in a given production area; this simplifies status configuration and shortens the startup time.
5. How quickly do operators learn to use the Andon system? The system is designed for ease of use at the workstation. The standard Andon colors—green, yellow, and red—are intuitive. Changing the status takes just a few seconds, and the double-confirmation option eliminates accidental calls. In practice, many operators become familiar with the system’s basic functions within a single shift, though this time depends on individual experience and the complexity of the configuration at a given workstation.
6. Can the Andon system be implemented in phases—for example, starting with a single production line? Yes, and this is the recommended approach. A phased implementation, starting with a single line or a few workstations, allows for learning without the risk of disrupting the entire production floor. It also provides time to tailor the configuration to actual needs before expanding the system to other production areas. AndonCloud supports any number of workstations and lines, so scaling the system does not require technical redesign.
7. What can go wrong when implementing an Andon system? The most common issues include the lack of a clear project owner on the company’s side, attempting to configure everything at once instead of in phases, excluding operators and shift supervisors from the testing process, and defining too many statuses at the outset, which leads to chaos rather than order.
8. What types of notifications can AndonCloud send? The system supports SMS, email, phone, and browser notifications. These can be configured separately for different roles and events. An operator sees different notifications than a maintenance manager, and a director receives only the information that requires their attention. Notifications can be active 24/7 or only during business hours.
9. Does AndonCloud allow you to measure OEE? Yes. The system generates OEE reports based on data collected automatically during workstation operations. You can view availability, performance, and quality in real time and compare results across shifts, lines, and periods. Recurring reports can be set up to generate automatically and be sent to designated recipients.
10. What does AndonCloud’s technical support look like after implementation? AndonCloud offers technical support through various communication channels, including 24/7 assistance for critical situations. This means that if a system issue arises in the middle of the night, you have access to help immediately, not just the next business day. This level of support is particularly important in continuous production or in a multi-shift work model.
Źródła
[1] Lean Enterprise Institute (2020). Getting the Right Information to the Right People at the Right Time: The Andon System in Practice. Cambridge, MA: LEI Press.
[2] Womack, J.P., Jones, D.T. (2003). Lean Thinking: Banish Waste and Create Wealth in Your Corporation (2nd ed.). Free Press.
[3] Shook, J. (2010). Managing to Learn: Using the A3 Management Process to Solve Problems, Gain Agreement, Mentor, and Lead. Lean Enterprise Institute.
[4] Liker, J.K. (2004). The Toyota Way: 14 Management Principles from the World's Greatest Manufacturer. McGraw-Hill.
[5] Eppler, M.J., Mengis, J. (2004). The Concept of Information Overload: A Review of Literature from Organization Science, Accounting, Marketing, MIS, and Related Disciplines. The Information Society, 20(5), 325–344.
