AiVibeIndustry 4.0 & Manufacturing Operations
Andon
Andon is a lean visual management system that signals the status of a process and alerts supervisors or support staff to problems, usually through lights, displays or sounds that an operator or a machine activates when an abnormality occurs.
The word andon comes from a Japanese paper lantern. In production, an andon system lets an operator pull a cord or press a button, or lets a machine trigger automatically, when there is a quality problem, a missing part, a breakdown or a need for help. A light tower, display board or audible signal shows which station has a problem, and a team leader responds. On some assembly lines, the line stops at a fixed position if the problem is not resolved within the cycle.
Andon is a practical application of jidoka, the Toyota Production System principle of stopping to fix problems rather than passing defects on. It shortens response times, makes problems visible to everyone and creates data on the frequency and causes of stops. Modern systems connect machine signals to digital dashboards, messaging and MES, recording response and resolution times for analysis.
An andon system only works when stopping or calling for help is genuinely encouraged and responders arrive promptly; otherwise operators stop using it. Clear escalation rules, defined colour meanings and response targets are important, and colour conventions should follow plant standards and the applicable machinery standards. Andon signals are informational and do not replace emergency stops or safety systems.
Key points
- Signals a problem at a station through lights, displays or sounds.
- Triggered by operators or automatically by machines.
- A practical application of jidoka: stop and fix rather than pass defects on.
- Informational only; it does not replace emergency stops or safety systems.
Where AiVibe comes in
AiVibe designs and manufactures the AiAmbA AI Factory as the OEM: edge devices plus AI agents that let people talk to PLC, CNC and robot controllers in plain language. Existing lines are retrofitted with edge devices, and a trained operator confirms every change an agent proposes.
Explore AiVibe’s work in Industry 4.0 & Manufacturing Operations →