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Module: Autonomation Element: Andon Systems: Training Pack
Module: Autonomation Element: Andon Systems: Training Pack
Module: Autonomation
Element: Andon Systems
Aims & Objectives
Purpose of Module : To explain what an Andon system is, and what are it’s
links to performance improvements
2
Agenda
4
Current understanding of Andon
5
What is Andon
Operator
DO Mgr
DO Team Leader
PUM
Shift Leader
Shift Leader
PUM
Team Leader
Mgr
SUPPORT
Operator HELP!
7
Different forms of Andon
An Andon can take many different forms from simple
indicator to complex control boards. All of them give
‘real time’ status of the performance of the given
area
1 2 3 4 5 6
1 2 3 4 5 6
NO
1 2 3 4 5 6
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What an Andon system does..
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What an Andon system doesn’t do
It doesn’t:-
! Solve Abnormalities
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Pre-requisites for an Andon system
Andon will not SOLVE Abnormalities, it can only highlight them
Cell
Leader
Team Team Team Team
Leader Leader Leader Leader
Team
Logistics SLA’s SLA’s Support Team
I Moveit
Leader
J. Bloggs George Stubbs
Tel: 12345 +Team SLA Tel: 11145
’s ’s
SLA
12
Types of Andon system
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Fixed Position Stop
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Moving Line stop
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Types of Andon Trigger
! Manual
Operator pushes button or pulls a cord
- Material call example
- Quality check, change over, etc.
! Automatic
A limit switch on a conveyor or on a chute
monitoring movement of parts
" Limit switch may monitor time and count the
number of parts passing through. (takt time)
" Andon can be activated by an error proofing
device
" Separate the man from the machine, freeing up
the operator to add value else where (Machine
shop)
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Examples of Andon Boards
Simple Andon System
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Andon criteria
Escalation Procedure
We are on plan
n n n
GREEN There are no
A ctio A ctio A ctio
issues o N o N o
N
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Escalation process
Stage 1
Once a abnormality is identified it is escalated to the next level to
eliminate it
If next level cannot eliminate it, then raise it to Shift Leader
Operator
Team Leader
Shift Leader
Mgr
21
Escalation process
Stage 2
Once all effort to solve the problem have been exhausted at Shift Leader
level, the problem is escalated to the highest level to avoid the line
stopping
Operator
Team Leader
Shift Leader
PUM
22
Setting up an Andon system
WHO - Operations Team
WHAT - Operations team must determine what production conditions need
to be monitored, and what Andon system meets their needs.
WHERE - Divide the operation into several processes stations and
assign each a process number or code and owner.
• Usually a small team per process number or code
• Post process numbers or codes at line side stations
WHY - To enable Operation teams to expose abnormalities with their
process, to help them eliminate them.
WHEN - The Andon system should only be installed after a robust
escalation procedure has been implemented
HOW - Document what the characteristics of the production line are and
gather data history for the line
• Establish Andon Procedures
• Audit procedure
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Lean Enterprise function of Andon Systems
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Guidelines
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Guidelines
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Opportunities
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