AndonCloud

The Andon system is one of the most important tools supporting modern production in the spirit of lean manufacturing. Its main task is to signal problems and disruptions in the production process in a simple, understandable, and immediate way. This allows production plants to respond quickly to failures, minimize downtime, and maintain high process quality.

What is the Andon system?

Andon is an information system that uses visual and audible signals to communicate the status of production. The most common elements are Andon lamps, which change color depending on the status of the workstation:

• green – work is proceeding according to plan,
• yellow – a disruption requiring attention has occurred,
• red – a failure or quality problem requiring immediate response.

In addition to light signals, the Andon system also uses sound signals and Andon boards. The boards serve as central screens displaying the current status of the line, the location of downtime, KPI indicators, and information about production targets. This makes communication on the shop floor simple and transparent.

How does Andon work in practice?

The Andon system does not fix problems, but signals and documents them. It can be activated automatically – e.g., when a machine detects an anomaly – or manually by an operator who notices a fault. The information is immediately forwarded to the responsible employees, such as the production leader, quality department, or maintenance department.

Modern Andon solutions allow for automatic recording of downtime and its causes. This makes it possible to analyze response times, the speed of handling reports, and the impact of failures on production indicators such as OEE (Overall Equipment Effectiveness).

Benefits of implementing the Andon system
Introducing Andon to a production plant brings measurable results:
reduction of downtime – faster detection and reporting of problems,

improved quality – immediate information about defects and errors,
increased productivity – shorter response times and better work organization,
clear communication – clear signals visible to all employees,
continuous improvement – data archiving and reports supporting trend analysis.

Andon and lean manufacturing

The Andon system originates from the Toyota Production System (TPS), which is the foundation of lean methodology. Its role is to support continuous process improvement (kaizen) by eliminating waste and responding quickly to disruptions. Today, Andon is used not only in the automotive industry, but also in electronics, pharmaceuticals, food processing, and many other sectors.

Summary

The Andon system is a modern tool for production visualization and downtime management that supports process efficiency, safety, and quality. Thanks to Andon lights, boards, and audible signals, employees have full control over the production process. The data collected by the system enables performance analysis and corrective action planning. Implementing Andon is a step towards more conscious, efficient, and competitive production.