Introduction to the ANDON system

As a core tool of lean manufacturing management, the ANDON system can quickly transmit information through the system when production defects/abnormalities are found during the manufacturing process, enabling rapid problem resolution; production can proceed smoothly, improving production efficiency. With continuous technological development, the ANDON system has evolved from the pull-cord mode to the mid-stage button mode, and then to the touchscreen mode. The touchscreen method makes information clearer and reduces unnecessary time waste.

The ANDON system provides operators with a new and more effective way to stop the production line. In traditional automotive production lines, once a fault occurs, the entire production line stops immediately. With the ANDON system, when a problem arises, operators can pull a cord or press a button at the workstation, triggering corresponding sounds and lighting up indicator lights to prompt supervisors to immediately identify the location and cause of the fault. Generally, problems can be resolved without stopping the entire production line, thereby reducing downtime while improving production efficiency.

Another main component of the ANDON system is information display. Displays are distributed in each workshop, hanging above the main aisle or near major processing equipment. The displays use FlexI/O drivers and can communicate with PLCs via remote I/O, facilitating system maintenance and expansion.

Each display panel of the ANDON system can provide information for a single production line, including production status, raw material status, quality status, and equipment status. The monitor can also display real-time data such as target output, actual output, downtime, and production efficiency.

According to Based on the information provided on the ANDON system display, operators can work more effectively. Additionally, different musical alerts allow operators and supervisors to clearly understand what issues have occurred within their jurisdiction. Team leaders or supervisors can also identify and eliminate bottlenecks in the production process based on the information shown on the display.

At the same time, team leaders or supervisors can monitor production status, raw material processing, and equipment operation status from the control room or remote monitoring stations. Using ANDON system monitoring, management can set system parameters and generate comprehensive information reports, including actual stop frequency, stop reasons, and stop request durations. Based on this information, engineers and supervisors can identify areas where processes can be improved or where operators need further training.