Picture this: an operator at a manufacturing plant spots a problem. To get help, they leave their station, walk 500 steps to find a supervisor, explain the issue, then walk 500 steps back—only to wait and hope someone shows up. As one industrial equipment manufacturer put it: "Right now my team's walking 500 steps to answer a call, then 500 steps back to where they just were."
This scenario plays out thousands of times daily in plants around the world. It's the problem Andon systems were designed to solve.
In this guide, you'll learn what an Andon system is, how it works, the problems it addresses, and when it makes sense for your operation. We'll draw on real examples from automotive, medical device, food and beverage, and general manufacturing facilities.
What Is an Andon System? Definition and Origin
An Andon system is an alert and notification system used on production floors to make problems visible immediately and get the right help to the right place—fast.
The word "Andon" (行灯) comes from Japanese and originally referred to a paper lantern. In manufacturing, it became the term for visual signals that indicate the status of a production line or workstation.
Andon systems emerged from the Toyota Production System in the mid-20th century as part of a broader philosophy called Jidoka—roughly translated as "automation with a human touch." The core idea: when a problem occurs, stop and address it immediately rather than letting defects flow downstream.
In its earliest form, Andon was a cord operators could pull to stop the line and signal for help. A light would illuminate above their station, and team leaders would respond. Today, Andon systems have evolved far beyond pull cords and lights, but the core purpose remains the same: make problems visible so they can be solved quickly.
As one medical device manufacturer described their system: "When they have a problem, they hit the button and our pager vibrates. We know it means somebody in one of our test cells needs help."
How Andon Systems Work: The Basic Flow
While implementations vary, most Andon systems follow a similar workflow:
1. Alert
An operator encounters an issue—a machine malfunction, a quality concern, a parts shortage, or a safety hazard. They trigger an alert, typically by pressing a button, pulling a cord, or activating a sensor.2. Notify
The system immediately notifies the appropriate responders. This might be maintenance, quality, materials handling, or a supervisor—depending on the type of issue. Notifications can come through lights, audible alarms, wearable pagers, digital displays, or mobile devices.3. Respond
A responder acknowledges the alert and heads to the station. Modern systems often track who responded and when.4. Resolve
The responder works with the operator to resolve the issue. Some systems track "time to fix" separately from "time to respond."5. Document
The call is closed, and the system logs the details: what happened, how long it took, who responded. This data becomes valuable for identifying patterns and driving improvement.As one operations manager explained the need: "When machines go down, we need to let the techs know they need to get up there and get it going." Andon systems make that notification instant and reliable.
Core Components of Any Andon System
Regardless of vendor or implementation, Andon systems typically include these core components:
Alert Devices
These are what operators use to signal for help:- Call buttons — Mounted at workstations, often with multiple keys for different call types (maintenance, quality, materials)
- Pull cords — Traditional method still used in some facilities
- Sensors — Automated triggers based on machine conditions or thresholds
Notification Devices
These deliver alerts to responders:- Visual signals — Stack lights, display boards, digital dashboards
- Audible alerts — Tones, chimes, or voice announcements
- Wearable devices — Pagers or watches that vibrate, especially useful in noisy environments
- Mobile notifications — Text messages, emails, or app alerts
Monitoring and Display
These provide visibility across the facility:- Andon boards — Large displays showing the status of all stations at a glance
- Dashboards — Computer-based views that can be filtered by area, department, or call type
- TV monitors — Placed throughout the plant for real-time visibility
Documentation and Reporting
These capture data for analysis:- Call logs — Record of every alert, response, and resolution
- Time tracking — Response time, repair time, total downtime
- Reports — Summaries by shift, station, call type, or responder
The Problems Andon Systems Solve
Understanding what Andon systems solve helps clarify when they're the right fit. Here are the most common problems they address:
Walking to Find Help
In facilities without Andon, operators often leave their stations to find assistance. A medical device company noted their operators were "going around looking for" help instead of staying at their stations. This creates multiple problems: the operator is away from their work, they might not find the right person, and there's no record of the request.
Andon systems let operators stay at their stations while the system handles notification.
Radios and Phones That Get Missed
Many plants try radios, walkie-talkies, or phone calls first. "Right now it's like a light or a radio—not everybody carries the radio," one plant manager explained.
A heavy vehicle manufacturer described a similar challenge: "The problem we run into is they're just using walkie-talkies to say 'I need such and such'—there's no record."
Radios have limitations: they require someone to be listening, calls can be missed in noisy environments, and there's no documentation of what was requested or when.
Calls That Go Unanswered
Without escalation, alerts can sit indefinitely. What happens when the first responder is busy, at lunch, or didn't hear the call?
Modern Andon systems address this with automatic escalation. Manufacturers want systems that automatically escalate when "a call goes over a specific allotted time." If the primary responder doesn't acknowledge within a set timeframe, the system alerts a backup or supervisor.
No Visibility for Management
Some plants rely on "basic maintenance alerts with stack lights"—but stack lights only work if someone's watching. Management has no way to see what's happening across the floor without physically walking the plant.
Andon dashboards and boards solve this by providing real-time visibility into which stations are calling, who's responding, and how long issues have been open.
No Data for Continuous Improvement
Many facilities describe their current state as "manual processes—walking and looking for supervisors." When everything is manual, there's no data to analyze. You can't identify patterns, prove bottlenecks, or measure improvement.
Andon systems capture every call, response, and resolution—creating the data foundation for Pareto analysis and targeted improvement efforts.
Industries That Use Andon Systems
Andon systems originated in automotive manufacturing but have spread across industries. Here's how different sectors use them:
Automotive and Tier-1 Suppliers
The birthplace of Andon. Assembly lines use it for line-stop alerts, quality concerns, and parts shortages. Response time is critical when the line is stopped.Medical Device Manufacturing
Clean room environments and test systems require quick response to equipment issues. Compliance documentation is often a secondary benefit.Food and Beverage
Sanitation requirements, temperature monitoring, and equipment reliability drive Andon adoption. FDA compliance makes documentation valuable.Aerospace and Defense
Long cycle times and high-value products mean any delay is costly. Traceability and documentation support compliance requirements.Heavy Equipment Manufacturing
Large facilities with long distances between stations make notification systems essential. Multiple departments—maintenance, materials, quality—need coordinated alerts.General Discrete Manufacturing
Any facility where operators need to call for help, and where response time and accountability matter, can benefit from Andon systems.When Andon Makes Sense (And When It Doesn't)
Andon systems aren't right for every situation. Here's an honest assessment:
Good Fit
- Multiple shifts — When you need consistent response regardless of who's on duty
- Response time matters — When delays directly impact production, quality, or safety
- Multiple responder types — When operators need to reach maintenance, quality, materials, or supervisors
- Data-driven improvement — When you want to identify bottlenecks and measure progress
- Noisy environments — When radios and PA systems aren't reliable
- Large facilities — When walking to find help is impractical
May Not Be Needed
- Very small operations — If everyone is within earshot and response is already fast
- Single-person shops — If there's no one to notify
- Low-stakes delays — If waiting a few minutes has minimal impact
- Tight budgets with no ROI — If downtime costs are low and improvement isn't a priority
Frequently Asked Questions
What does "Andon" mean?
Andon (行灯) is a Japanese word originally meaning "lantern" or "lamp." In manufacturing, it refers to visual signals and alert systems that indicate production status or problems.What's the difference between Andon and stack lights?
Stack lights are passive visual indicators—they show status, but only if someone is watching. Andon systems are active: they proactively notify specific people when help is needed, track response times, and escalate if calls go unanswered.Do Andon systems require a computer?
Basic systems can work without a computer—just buttons and pagers. However, most modern implementations include software for configuration, dashboards, and reporting. The software typically runs on a standard Windows PC.How is Andon different from a PA system or radios?
PA systems and radios are broadcast communication—everyone hears everything, and there's no record of who responded. Andon systems are targeted and tracked: the right person gets notified, response times are measured, and calls escalate if unanswered.Is Andon only for automotive manufacturing?
No. While Andon originated in automotive (specifically Toyota), it's now used across industries including medical devices, food and beverage, aerospace, heavy equipment, and general manufacturing.Ready to Explore Andon Systems?
Now that you understand what Andon systems are and how they work, you might be wondering how to evaluate options for your facility.
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