The Andon system is a core component of Jidoka, a crucial principle in Lean Manufacturing. Jidoka comprises three key elements: Andon systems, full work systems, and error-proofing (Poka-yoke).
So, what exactly does an Andon system entail? Essentially, it’s a visual management tool designed to immediately alert personnel to abnormalities or problems within a production process. This allows for prompt corrective action and streamlined workflow.
Here’s what an Andon system achieves:
* Facilitates timely corrective actions by immediately alerting personnel to abnormal conditions.
* Frees up Shop floor Team Leaders to focus on problem-solving rather than constant monitoring.
* Enables operation teams to monitor equipment and personnel more efficiently.
* Provides two-way communication, signaling when an issue is resolved (e.g., a green indicator).
However, it’s important to understand the limitations of an Andon system:
* It doesn’t solve abnormalities on its own; it merely highlights them.
* It doesn’t prevent all defects.
* It doesn’t replace clear verbal communication between teams.
* It doesn’t eliminate the need for rectification or customer protection measures.
The direct benefits of Andon systems include:
* Improved production control: Operators can initiate a ‘stop, call, wait’ protocol when necessary.
* Enhanced defect reporting and correction: Operators can immediately report issues, enabling quick countermeasure implementation.
* Improved safety and ergonomics: Andon systems can highlight safety concerns and potential ergonomic stressors.
* Balanced workloads: Facilitates process rebalancing to prevent overburdening.
* Improved Workable Design: Highlights problems with work density.
To effectively implement an Andon system, consider these guidelines:
* Implement Andon only after establishing Standard Operations to ensure stability.
* Define team structure, ratios, roles, and responsibilities clearly.
* Identify specific work zones and stations.
* Divide the overall process into manageable steps.
* Determine the key conditions that need to be measured and monitored.
* Design a clear and easily understandable Andon board.
* Establish a clear escalation procedure for addressing different types of issues.
* Define the support structure that will maintain and improve the Andon system.
* Set criteria for downtime data collection and analysis.
* Establish regular confirmation points and review processes.
* Implement an effective communication structure to disseminate information quickly.
* Visually track the status of problem-solving efforts.
Key considerations for successful implementation:
* Andon systems should be thoughtfully designed and tailored to the specific needs of the environment.
* Implement Andon only when a robust support system and escalation procedure are in place.
* Andon signals must be simple, clear, and easy to understand.
* Start with a simple, manual system to assess its value before investing in a sophisticated, automated solution.