ANDON

WISNU AKBAR NUGRAHA

Safety and Improvement Process Officer
 What is Andon ?
Andon

Japanese translation: Lantern

A visual control that enables the operator to inform the Team

Leader (or responsible line cover) that an abnormal condition
exists.
Note: IT IS NOT A TOOL TO STOP THE LINE, IT IS
IN FACT A TOOL TO KEEP THE LINE RUNNING
Page
2
 PLAN 153 LINE 1 PROD 146

Process Control Overview 12:05 DOWN 021

Vehicle Flow Andon PRE HELP

EQUIP

QUALITY
1 2 3

SYSTEM HEALTHY
4 5 6
PST

ONE TOUCH ONE TOUCH ONE TOUCH ONE TOUCH

FIRST TIME FIRST TIME FIRST TIME FIRST TIME
EVERY
10% 30%
TIME
50% 70% 90%
EVERY TIME EVERY TIME EVERY TIME

L10 L10 L10 L10

H A L EW O O D Yamazumi Board
Team: GL X1: GL X2: Last Update:

Yamazumi Key:
Work Classification Working Position
R1 R2 R3 R4
Value Added Work
C1 C2 C3 C4
Non-Value Added Work L1 L2 L3 L4

Essential NVAW
S1

Option Work
Icons
Associated Associated Quality
Variant Work ENVAW NVAW Critical

15%
85%
5%
Time – 1sec=5mm

40%

60%

35%

Page
Retractor LH Retractor RH Carpet Fit

Processes
Loom

3
Is activated by :
Andon
the process operator manually
automatically by links to equipment

Provides real time information.

Trigger for problem solving.

Prevents concerns being passed onto the next

process ie Supports JIDOKA

Key driver towards Lean Manufacturing.

Page
4
PULL IF QUALITY OR SAFETY ISSUE
PULL TO ALERT T/L OF ANY
ABNORMALITY
STOP- CALL- WAIT

20 March Pag
2019 e5
PROBLEM INDICATION RESPONSE
20 March Pag
2019 e6
What does it look like ?

Simple to read. Andon

Information easy to understand at a glance.

Prominent location for the line support to see.

Shows location of the concern, not detail.

PLAN 153 LINE 1 PROD 146
12:05 DOWN 021
1 2 3 4 5 6
PRE HELP PST

EQUIP
QUALITY
SYSTEM HEALTHY Page
7
 Andon
PLAN 153 LINE 1 PROD 146

Hardware overview: 12:05

1 2 3 4 5 6
DOWN 021

PRE HELP PST

EQUIP
QUALITY

Pull cords and beacons

SYSTEM HEALTHY
 Andon
How does it work ? Line running

PLAN 153 LINE 1 PROD 146

12:05 DOWN 021

ATTEND 1 2 3 4 5 6
PRE HELP PST

CRD EQUIP
QUALITY P

SYSTEM HEALTHY
 Andon
How does it work ? Concern - Cord Pulled
Pull cords and beacons

PLAN 153 LINE 1 PROD 146

12:05 DOWN 021

1 2 3 4 5 6
PRE HELP PST
EQUIP
QUALITY
SYSTEM HEALTHY
 Andon
How does it work ? Relevant position
lights up

PLAN 153 LINE 1 PROD 146

12:05 DOWN 021

ATTEND 1 2 3 4 5 6
PRE HELP PST

CRD EQUIP
QUALITY P

SYSTEM HEALTHY
Marquee PLAN 153 LINE 1 PROD 146

12:05

PRE HELP
1 2 3 4 Andon
5 6
DOWN 021

PST
EQUIP
QUALITY
SYSTEM HEALTHY

The marquee shows the following information:

System healthy

Production Held Information

System fault Information

Emergency Stop information

Buffer warning levels

Maintenance Call Information

Chimes
Andon

The purpose of the chimes is to alert the personnel in that area that
there has been a change in status on either the line side equipment or
on the local Andon board.
Every team on the line is allocated a sounder. Each sounder has the
ability to sound individual chimes.
Every line is usually allocated two chimes:
1st chime is for the purpose of warning the local team.
2nd chime is for the purpose warning the whole line.
De-coupling and Managed Buffers.
Andon
Effective use of an Andon system relies upon the introduction
of de-coupled production lines with managed buffers.

De-coupled lines allow production areas to stop without

immediate effect to following and preceding areas.

It ensures that, within reason, a continuous flow of

production is maintained by using the managed buffers
between the lines.

Pag
e 14
De-coupling and Managed Buffers.
Andon
Total line stop
Stn 1 Stn1 - Stn 60 Stn 60

Line stop

Stn 1 Stn 20 Stn 41 Stn 60

Line stop
Line stop Stn1-Stn20 Managed buffers

Production continues
until preceding buffer
Stn 21 Stn 40 short

20 March Pag
2019 e 15
 How big should the buffer be?

How to manage the buffer?

Set the buffer quantity based upon the line performance / downtime

Reduce buffers
as pulls &
downtime
reduce
No of
10 mins ~ 5 cars
pulls (depends on Takt)

1 2 3 5 10 20
Time in secs
20 March Pag
2019 e 16
TERIMA KASIH