Andon (manufacturing): Difference between revisions
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{{Short description|Alerting system for quality control}}{{More citations needed|date=September 2019}} |
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{{Other uses|Andon (disambiguation)}} |
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[[file:Andon Otomasyon Panosu2.jpg|thumb|Signboard]] |
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| ⚫ | In [[manufacturing]], '''andon''' ({{lang-ja|アンドン or あんどん or 行灯}}) is a system which notifies managerial, maintenance, and other workers of a [[Quality control|quality]] or [[Manufacturing process management|process]] problem. The alert can be activated manually by a worker using a pullcord or button or may be activated automatically by the production equipment itself. The system may include a means to pause production so the issue can be corrected. Some modern alert systems incorporate audio alarms, text, or other displays; [[stack light]]s are among the most commonly used. |
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An Andon System is one of the principal elements of the [[Jidoka]] [[Quality control|quality-control]] method pioneered by Toyota as part of the [[Toyota Production System]] and therefore now part of the [[Lean production|Lean]] approach.<ref>Liker, Jeffrey (2004) "The Toyota Way" New York:McGraw Hill {{ISBN|0-07-139231-9}}</ref><ref>[http://www.emeraldinsight.com/doi/abs/10.1108/EUM0000000001635 Robert J. Everett & Amrik S. Sohal, (1991) "Individual Involvement and Intervention in Quality Improvement Programmes: Using the Andon System", International Journal of Quality & Reliability Management, Vol. 8 Iss: 2]. Accessed 5 December 2014</ref> It gives the worker the ability, and moreover the empowerment, to stop production when a defect is found, and immediately call for assistance. Common reasons for manual activation of the Andon are part shortage, defect created or found, tool malfunction, or the existence of a safety problem. Work is stopped until a solution has been found. The alerts may be logged to a database so that they can be studied as part of a continuous-improvement program. |
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“Andon” is a [[loanword]] from Japanese, originally meaning [[traditional lighting equipment of Japan|''paper lantern'']]; Japanese manufacturers began its quality-control usage.<ref>{{Cite web |last=Blog |first=Toyota |date=2016-05-31 |title=Andon - Toyota Production System guide |url=https://mag.toyota.co.uk/andon-toyota-production-system/ |access-date=2024-05-09 |website=Toyota UK Magazine |language=en-GB}}</ref> |
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| ⚫ | The system typically indicates where the alert was generated, and may also provide a description of the |
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==Details== |
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| ⚫ | The concept/process of giving a non-management (production line) worker the authority to stop the production line because of a suspected quality issue is |
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[[File:Papan Andon Baru (2009?) di dalam kilang Cummins India Limited.png|thumb|Andon board displays used inside Cummins India Limited]] |
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An andon system is one of the principal elements of the [[Jidoka]] [[quality control]] method pioneered by Toyota as part of the [[Toyota Production System]] and therefore now part of the [[lean production]] approach. |
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The principle of Andon works as such: if there are any production issues happening in Production line, the affected work station operator will need to trigger alert by pulling down the andon cord. But since 2014, Toyota is slowly replacing the andon cord with "andon button" as it can be operated wirelessly and reduce the clutter mess of tangling cables in production floor which leads to avoidance of tripping incidents in production floor.<ref name="AutoVW-1"/><ref name="AutoVW-2"/> It gives workers the ability, and moreover the empowerment, to stop production when a defect is found, and immediately call for assistance. Common reasons for manual activation of the andon are: |
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* Part shortage |
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* Defects created or found |
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* Tools/machines malfunction |
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* Existence of a safety problem. |
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All work in production line is stopped until a solution has been found. The alerts may be logged to a database so that they can be studied as part of a [[continual improvement process]]. Once the problem is troubleshot and fixed, a second pull of the andon cord authorizes the production to be resumed. |
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| ⚫ | The system typically indicates where the alert was generated, and may also provide a description of the issue. Modern andon systems can include text, graphics, or audio elements. Audio alerts may be done with coded tones, music with different tunes corresponding to the various alerts, or prerecorded verbal messages. |
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==History== |
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| ⚫ | The concept/process of giving a non-management (production line) worker the authority to stop the production line because of a suspected quality issue is often attributed to [[W. Edwards Deming]] and others who developed what became [[Kaizen]] after World War II. Many attribute Japan's rise from wartime ashes to the world's second largest economy (the [[Japanese economic miracle]]) to their post-war industrial innovations: |
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* Better design of products to improve service |
* Better design of products to improve service |
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* Greater sales through side [global] markets |
* Greater sales through side [global] markets |
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Usage of the word originated within [[Japan]]ese manufacturing companies, and in English is a [[loanword]] from a Japanese word for a [[Traditional lighting equipment of Japan|paper lantern]]. |
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==References== |
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{{reflist|refs= |
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{{Reflist}} |
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<ref name="AutoVW-1">Liker, Jeffrey (2004) "The Toyota Way" New York:McGraw Hill {{ISBN|0-07-139231-9}}</ref> |
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<ref name="AutoVW-2">[http://www.emeraldinsight.com/doi/abs/10.1108/EUM0000000001635 Robert J. Everett & Amrik S. Sohal, (1991) "Individual Involvement and Intervention in Quality Improvement Programmes: Using the Andon System", International Journal of Quality & Reliability Management, Vol. 8 Iss: 2]. Accessed 5 December 2014</ref> |
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<!--<ref name="Toyota">{{cite web |title=Toyota cutting the andon cord, symbol of Toyota Way |url=https://europe.autonews.com/article/20140805/ANE/308059902/toyota-cutting-the-andon-cord-symbol-of-toyota-way |website=Automotive News Europe |language=en |date=5 August 2014}}</ref>--> |
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}} |
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[[Category:Japanese business terms]] |
[[Category:Japanese business terms]] |
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[[Category:Manufacturing in Japan]] |
[[Category:Manufacturing in Japan]] |
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[[Category:Toyota Production System]] |
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Latest revision as of 02:37, 9 May 2024
 | This article needs additional citations for verification. (September 2019) |
In manufacturing, andon (Japanese: アンドン or あんどん or 行灯) is a system which notifies managerial, maintenance, and other workers of a quality or process problem. The alert can be activated manually by a worker using a pullcord or button or may be activated automatically by the production equipment itself. The system may include a means to pause production so the issue can be corrected. Some modern alert systems incorporate audio alarms, text, or other displays; stack lights are among the most commonly used.
“Andon” is a loanword from Japanese, originally meaning paper lantern; Japanese manufacturers began its quality-control usage.[1]
Details[edit]
An andon system is one of the principal elements of the Jidoka quality control method pioneered by Toyota as part of the Toyota Production System and therefore now part of the lean production approach.
The principle of Andon works as such: if there are any production issues happening in Production line, the affected work station operator will need to trigger alert by pulling down the andon cord. But since 2014, Toyota is slowly replacing the andon cord with "andon button" as it can be operated wirelessly and reduce the clutter mess of tangling cables in production floor which leads to avoidance of tripping incidents in production floor.[2][3] It gives workers the ability, and moreover the empowerment, to stop production when a defect is found, and immediately call for assistance. Common reasons for manual activation of the andon are:
- Part shortage
- Defects created or found
- Tools/machines malfunction
- Existence of a safety problem.
All work in production line is stopped until a solution has been found. The alerts may be logged to a database so that they can be studied as part of a continual improvement process. Once the problem is troubleshot and fixed, a second pull of the andon cord authorizes the production to be resumed.
The system typically indicates where the alert was generated, and may also provide a description of the issue. Modern andon systems can include text, graphics, or audio elements. Audio alerts may be done with coded tones, music with different tunes corresponding to the various alerts, or prerecorded verbal messages.
History[edit]
The concept/process of giving a non-management (production line) worker the authority to stop the production line because of a suspected quality issue is often attributed to W. Edwards Deming and others who developed what became Kaizen after World War II. Many attribute Japan's rise from wartime ashes to the world's second largest economy (the Japanese economic miracle) to their post-war industrial innovations:
- Better design of products to improve service
- Higher level of uniform product quality
- Improvement of product testing in the workplace and in research centers
- Greater sales through side [global] markets
See also[edit]
- Traditional lighting equipment of Japan § Andon
- Stack light (commonly used in andon and lean manufacturing initiatives)
References[edit]
- ^ Blog, Toyota (2016-05-31). "Andon - Toyota Production System guide". Toyota UK Magazine. Retrieved 2024-05-09.
- ^ Liker, Jeffrey (2004) "The Toyota Way" New York:McGraw Hill ISBN 0-07-139231-9
- ^ Robert J. Everett & Amrik S. Sohal, (1991) "Individual Involvement and Intervention in Quality Improvement Programmes: Using the Andon System", International Journal of Quality & Reliability Management, Vol. 8 Iss: 2. Accessed 5 December 2014