A brief overview of the ANDON system

As the 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-wire mode to the mid-term 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 to trigger corresponding sounds and light up the corresponding indicator lights, prompting supervisors to immediately identify and address the fault location. Generally, the cause of failure can be resolved without stopping the entire production line, thereby improving production efficiency while reducing downtime.

Another main component of the ANDON system is information display. Displays are distributed in each workshop, hanging above the main aisles or near major processing equipment. The displays use FlexI/O drive and can communicate with PLC 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. In addition, different musical alerts allow operators and supervisors to clearly understand what issues are occurring within their jurisdiction. Team leaders or supervisors can also identify and eliminate bottlenecks in the production process based on the information displayed on the screen.

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 for process improvement or areas where operators need further training.