Andon board
Andon board is related with production. It is a part of a lean manufacture system. Andon board is an electric light board used in production line in factories for visual control of tracking defective work in assembly lines. Located in a central part, andon board is well seen by a team members and a supervisors. Board has a numbers or names which specify the status of each process and that is why team members are aware of proceedings in their line. Visual indicator such as coloured light signaling that worker has found an abnormal situation like missing parts, poor quality, problem with the parts, missing information etc. Immediately everyone is informed about the problem and where it has been caused[1][2][3][4].
The origin
Andon board comes from Japan. "Andon" is a Japanese word means lamp[5]. Andon was first used in a Toyota Production System (TPS). It was a foundational element of manufacturing in Toyota as a part of jidoka or build-in quality. Now, andon board is in use in a most of manufactures[6].
Usage of the andon board
Andon board is very easy to use. A green light is on when a line is going well. If worker indicates a problem, he pushes a button or pulls a cord and the yellow light is litted on the andon board. Supervisors diagnose what happened and can call for help. They try to resolve a problem quickly to be able keep working in time. The red light turns on when job is not completed or the problem is acute. With red, all line stops and every worker with it. In a meanwhile team members have time to rest, prepare parts, go to help, fullfil bins. After solving a problem, short break is over and a line keeps running. For workers andon board makes an atmosphere of a real team[7][8].
Meaning of a colour on the andon board
Andon board is equipped with a few various colour of call lights[9]:
- green light - normal process
- yellow light - line is having a problem, delay in process
- red light - stop the process
Examples of Andon board
- Visual Display Board: This is a physical board which displays a real time status of the production process. It can be used to display a wide range of information such as production numbers, quality checks, or inventory levels. It is usually located in a central area of the factory, so it is easily visible by team members and supervisors. The board typically consists of lights, colors, or numbers which indicate the status of each process.
- Digital Andon Board: This type of Andon board is becoming increasingly popular in factories. It works in the same way as the visual display board, but instead of physical lights, the board is digital and is connected to the factory’s computer system. This allows for more detailed information to be displayed and for the board to be updated in real time.
- Voice Activated Andon Board: This type of Andon board is useful in situations where a visual display is not practical. The board is connected to the factory’s computer system and when a problem is detected, it can be programmed to activate a voice alert. This alert can then be heard by team members and supervisors and the problem can be addressed quickly.
- Mobile Andon Board: This type of Andon board is designed to be used in areas where a permanent installation is not practical. It is a portable board which can be set up quickly in any area of the factory. It typically consists of a panel with lights, colors, or numbers which indicate the status of the process. The panel can be connected to the factory’s computer system and can be updated in real time.
Advantages of Andon board
Andon board is a useful tool for production line workers, supervisors and team members. It offers several advantages, such as:
- Real-time monitoring of production line: Andon board allows for tracking of defects in assembly lines in real-time, which increases efficiency and effectiveness of the production line.
- Improved communication: Andon board makes it easier for team members and supervisors to communicate, since everyone is aware of the status of each process at all times.
- Improved quality: By providing a visual indicator to signal a problem, Andon board helps in detecting and solving any quality issues before they become too severe.
- Reduced waste: Andon board helps in reducing waste, since any issues can be quickly identified and corrected, preventing any further waste.
Limitations of Andon board
Andon board, as an effective tool for visual control of tracking defective work in assembly lines, has some limitations:
- It does not identify the root cause of the problem, since it just identifies the process in which the problem occurred.
- It does not provide feedback on how to prevent the problem from reoccurring in the future.
- It does not provide information on how to improve the process.
- It can lead to over-reaction or under-reaction in certain cases, making it difficult to take the appropriate corrective action.
- It can be expensive to install and maintain.
- It can be time-consuming to interpret the data, making it difficult to implement timely corrective action.
- It can be difficult to interpret the data if the layout of the andon board is not designed properly.
- It can be difficult to update and make changes to the andon board in order to improve the system.
- Kaizen events: these are continuous improvement events that involve all team members in the process of identifying problems and finding solutions to them.
- Poka-yoke: this approach focuses on preventing errors by using simple devices, such as guards, light signals, and warning labels.
- Standardized work: this approach helps to ensure that all processes are done in the same way every time, eliminating inconsistencies and errors.
- Visual controls: this approach involves using visual cues such as colour-coded charts and light signals to help workers identify problems quickly.
In summary, Andon board is a tool used in lean manufacturing to help track and address problems in assembly lines. Other approaches related to Andon board include Kaizen events, Poka-yoke, standardized work and visual controls. All of these are designed to help identify and address problems quickly and efficiently.
Footnotes
- ↑ Hill A. (2012), p.28
- ↑ Stewart J.(2011), p.51
- ↑ Boyer R., Charron E., Jurgens U., Tolliday S. (1998)
- ↑ Monden Y. (2011)
- ↑ Hill A. (2012), p.28
- ↑ Stewart J. (2011)
- ↑ Boyer R., Charron E., Jurgens U., Tolliday S. (1998)
- ↑ Black J.T., Hunter S. (2003), p.97
- ↑ Boyer R., Charron E., Jurgens U., Tolliday S. (1998)
| Andon board — recommended articles |
| Andon — Autonomous maintenance — Andon cord — Breakdown maintenance — 5S method — Quality assurance — Konnyaku stone — Jidoka — Quality control |
References
- Black J.T., Hunter S. (2003)Lean Manufacturing Systems and Cell Design, Society of Manufacturing Engineers
- Boyer R., Charron E., Jurgens U., Tolliday S. (1998), Between Imitation and Innovation: The Transfer and Hybridization of Productive Models in the International Automobile Industry, OUP Oxford
- Hill A. (2012), The Encyclopedia of Operations Management: A Field Manual and Glossary of Operations Management Terms and Concepts, FT Press
- Monden Y. (2011)Toyota Production System: An Integrated Approach to Just-In-Time, 4th Edition, CRC Press
- Stewart J. (2011), The Toyota Kaizen Continuum: A Practical Guide to Implementing Lean, CRC Press
Author: Weronika Lisik
