Andon boards have become a staple in modern manufacturing, and for good reason. Andon boards are a visual communication tool that helps workers understand their workflow – and where they are in it – at a glance.
The result of successful andon board implementation is improved productivity and efficiency on the shop floor. If you’re involved in managing or working in a manufacturing environment, you’ve likely encountered the term “andon board” or “andon cord.” But what exactly is it, and why has it become such a staple facet in today’s industrial settings?
In this article, we’ll explain what andon boards are, how they work, their benefits, and how IIoT platforms can integrate your current andon boards to streamline workflows.
What Is an Andon Board?
An andon board is a visual control device that is used on the shop floor to communicate the status of production processes in real time. Typically, these boards display information such as the status of machinery, production targets, and any issues or delays that arise during the manufacturing process. The concept originated from the Japanese manufacturing industry, particularly Toyota’s production system, and has since been adopted globally as a key element of lean manufacturing.
An andon board is often connected to a signaling system, such as color-coded lights or alarms. These signals are easy to understand at a glance: green for normal operation, yellow indicates a warning, and red signifies an issue that needs immediate attention. This simple yet effective system speeds up response time, minimizes downtime, and prevents small issues from escalating into major production halts.
The Role of Andon Boards in Lean Manufacturing
Lean manufacturing focuses on reducing waste, optimizing processes, and delivering value to the customer. Andon boards are central to lean manufacturing as they provide transparency and clear direction on the shop floor. In other words, they make it easier for your team to identify and address problems, or even inefficiencies, in real-time.
Here’s how it works: when one of your operators encounters a problem they can trigger the andon system which immediately notifies shop floor management. In lean manufacturing, time is as much of a resource as money. This quick action and response from management and repair technicians helps save time and resources, and therefore money.
On top of that, andon boards promote a culture of continuous improvement – one of the 5S principles of lean manufacturing. Because andon boards live on the shop floor and are readily accessible by all staff, everyone from operators to management can get in on finding solutions. This constant feedback loop helps teams improve operations on an incremental, day-to-day basis.
5 Benefits of Andon Boards
Andon boards have undeniable benefits when it comes to streamlining production operations and improving clarity on the shop floor. Here are five:
1. Better Communication
One of the primary benefits of andon boards is the improvement in communication. With andon boards, there is no question about what is happening on the shop floor. All team members are on the same page with clear directives.
2. Reduced Downtime
Andon boards help identify and address issues quickly, which reduces employee and machine downtime. Whether it’s a machine malfunction or a supply chain delay, the sooner you know about the problem, the faster you can resolve it.
3. Employee Accountability
With andon boards, it’s easy to see who is responsible for each part of the production process. This visibility encourages accountability, as employees know their actions (or inactions) are being monitored in real time.
4. Data-Backed Decision-Making
Having access to real-time data allows managers to make more informed decisions. When you can see exactly what’s happening on the shop floor, you can react more effectively to issues and make adjustments that improve performance.
5. Continuous Improvement
Again, andon boards give all employees a voice that can herald in that lean manufacturing principle of continuous improvement. Teams are in a better position to address the root cause of issues rather than only treating symptoms. You’ll also find employees are more engaged in their work as they can see their impact on workflows.
The Evolution of Andon Boards: From Manual to Digital
Traditionally, back when Toyota was pioneering lean manufacturing concepts in the 1950s and 60s, andon boards were manually operated, often consisting of simple lights or signs that were updated by hand. It was a start, but as we know today, manual systems have limitations. As companies have grown in size, we’ve discovered these issues exponentially affect large-scale operations where real-time accuracy is make or break.
Industry 4.0 has completely revolutionized this system (among others). Today, andon boards can be integrated with advanced software solutions like Enterprise Resource Planning (ERP) systems and Industrial Internet of Things (IIoT) software.
Digital andon boards can now be connected to IIoT devices like machines, sensors, programmable logic controllers (PLCs), human-machine interfaces (HMIs), and other data sources across the shop floor. With IIoT-enabled andon boards, you can access automatic updates, more detailed data collection, and seamless integration with other systems.
For example, a digital andon board can automatically display machine status based on input from sensors, eliminating the need for manual updates. On top of that, these systems can track trends over time, providing valuable insights to your manufacturing business.
Industrial IoT and Andon Boards: A Powerful Partnership
IIoT systems are transformative technologies that connect machines, devices, systems, and people in industrial environments like machine shops, smart factories, and any other manufacturing setting.
IIoT platforms collect and analyze data in the moment. When combined with andon boards, IIoT enhances their capabilities, turning them from simple visual tools into integral parts of a smart manufacturing ecosystem.
Here’s how IIoT and andon boards work together:
Shop Floor Monitoring and Alerts
IIoT systems collect data from all WiFi-enabled machines and sensors on the shop floor. This data is fed into the andon board, providing an overview of the entire production process in the moment. If a machine starts to malfunction, the IIoT system can immediately trigger an alert on the andon board, allowing operators to take swift action.
Work with More Data, Faster
When you integrate IIoT systems with andon boards, you can access detailed data about every aspect of the production process. Of course, it can be overwhelming to work with such a wealth of data, but IIoT systems and integrated systems like ERP can boil data down into easy-to-read dashboards, not unlike andon boards. The collected data can be analyzed to identify patterns, predict issues before they occur (similar to predictive maintenance), and implement preventative measures, further reducing downtime.
Automatic Actions
Advanced IIoT systems can go a step further by automating certain responses to andon alerts. For example, if a machine exceeds a certain temperature threshold, the IIoT system could automatically shut it down to prevent damage, while the andon board updates to display the relevant information.
Scalable and Flexible
IIoT-enabled andon boards can easily scale with your business. As your production processes evolve, these systems can be updated and reconfigured without the need for significant infrastructure changes. This flexibility makes it easy to adapt to new challenges and opportunities as they arise.
Remote Monitoring and Control
With IIoT, you’re not limited to monitoring the andon board on the shop floor. You can access real-time data from anywhere. This means you’ll know about and be able to address problems that happen on overnight shifts or when you’re out in the field. This is particularly valuable for multi-site operations where centralized monitoring and decision-making are imperative.
ProphecyIoT: Leverage Andon Boards for Better Shop Floor Management
At ProphecyIoT, we understand the importance of integrating traditional manufacturing tools like andon boards with cutting-edge IIoT technology. Our solutions are designed to enhance the functionality of andon boards, turning them into powerful data-driven tools that provide more than just visual feedback.
With ProphecyIoT, you can expect:
- Seamless Integration: Our IIoT platform easily integrates with your existing andon board systems, enhancing their capabilities without the need for extensive infrastructure changes.
- Real-Time Data and Alerts: Get real-time insights into your production processes and respond quickly to issues as they arise.
- Advanced Analytics: Use the data collected from your andon boards and IIoT systems to drive continuous improvement.
- Scalability: As your business grows, our solutions scale with you, providing the flexibility you need to meet new challenges head-on.
The future of manufacturing is here, and it’s smarter, more connected, and more efficient than ever before. If you’re ready to experience digital transformation at its finest, contact our experts to schedule a consultation today.
