Andon System
Summary
TLDRThe video explains the concept of an Andon system, a signaling tool used in production environments to monitor and alert about the status of a production line. It uses visual signals, like green, amber, and red lights, to indicate whether the line is running smoothly, paused, or experiencing issues. The system can be connected to computers or databases for remote monitoring. Additionally, Andon boards display key performance metrics, such as production targets and shifts, helping management identify problems and optimize performance across various shifts and lines.
Takeaways
- 💡 Andon is a signal or alerting tool used to identify problems in production lines.
- 🚦 The Andon system typically uses a light system with green, amber, and red lights to indicate the status of a production line.
- ✅ A green light means the production line is running smoothly without any issues.
- ⏸️ An amber or yellow light signals that the line is paused, either by operator input or an automatic sensor.
- 🛑 A red light indicates a significant problem, and the production line may be stopped or shut down.
- 🖥️ Andon systems can be integrated with PLCs and computers, allowing remote monitoring of production line status.
- 🔄 Andon signals can be connected to databases for real-time updates and remote access for engineers or managers.
- 📊 Andon boards provide detailed production line data, such as shift targets and performance metrics.
- 🔍 Andon boards are useful for identifying issues, such as a shift not meeting its production target, prompting management to investigate.
- 📉 Different types of Andon boards can display specific statuses like 'line running,' 'jammed,' or 'needs material,' providing a clear overview of the production line health.
Q & A
What is an Andon system?
-An Andon system is a signal or alerting tool used in production environments to indicate the status of a process or machine. It can take the form of a light system or an Andon board.
What do the different colors of the Andon lights signify?
-In the Andon system, green indicates the production line is running well without issues, amber or yellow means the line is on hold or paused, and red signifies a larger problem, potentially shutting the line down completely.
How does an Andon system help in production management?
-The Andon system alerts workers or management when there are issues on the production line, allowing them to address problems quickly. It can also be linked to databases and computers, enabling remote monitoring of the line's status.
What might cause the Andon light to turn amber/yellow?
-An amber or yellow light typically indicates that the line is paused, possibly due to operator input, a sensor stopping the line temporarily, or issues like line balancing.
How does the Andon system support remote monitoring?
-The Andon system can be connected to databases or computers, allowing process engineers or management to monitor the production line remotely through software, even if they are in a different location.
What example is given to explain a red light on the Andon system?
-A red light in the Andon system indicates a larger issue where the production line may have stopped entirely, requiring immediate attention to resolve the problem.
What additional information can be displayed on an Andon board?
-An Andon board can display information such as shift targets, current production numbers, and line status (e.g., running, jammed, needs material), giving an overview of the production line's health.
What does the shift target information on the Andon board signify?
-The shift target information shows the expected number of units to be produced during each shift. It compares actual production to the target, indicating any discrepancies between planned and actual output.
How can an Andon system trigger problem-solving in management?
-The Andon system can highlight issues such as missed production targets or downtime, prompting management to investigate and address the root causes, such as underperformance on a specific shift.
What is one of the key benefits of using Andon systems in production environments?
-One of the key benefits of using Andon systems is the ability to quickly identify and resolve problems on the production line, minimizing downtime and improving overall efficiency.
Outlines
💡 Introduction to Andon System
This paragraph introduces the concept of an Andon system, explaining that it is an alerting tool used to signal or indicate the status of a production line. The system typically uses lights (green, amber, red) to represent different operational states of the line. Green indicates the line is functioning well, amber signals a temporary halt (due to capacity or balance issues), and red signifies a more serious issue that may have caused the line to stop completely. The Andon system helps operators and engineers monitor and maintain the production line's health.
🔍 Andon in Production Line Monitoring
Here, the paragraph dives deeper into the visual and operational aspects of the Andon system within a production line. The speaker describes a packaging line and highlights various Andon signals visible across the workspace, explaining their role in identifying problems. The Andon system provides real-time updates about production status and can be linked to PLCs and databases, allowing remote monitoring. A process engineer, for example, can stay informed about line performance from another location, receiving updates on whether the line is running smoothly or facing issues.
🔴 Andon Lights: A Closer Look
This section focuses on specific examples of Andon signals embedded in the production line. The speaker points out several lights circled in the image, explaining that these are part of the overall Andon system. These lights are not the only signals, as Andon covers a broader system designed to notify staff about potential issues. By integrating these lights at workstations, employees can quickly identify and address problems, ensuring smoother production flow.
📊 Andon Boards: Displaying Production Metrics
The paragraph introduces Andon boards as another form of the system, showcasing examples from a Google search. These boards provide detailed data about production targets, performance, and issues during different shifts. For instance, the speaker explains a specific board displaying shift targets and actual production numbers, showing that the night shift fell short of its target. Such information allows management to investigate issues and improve processes on underperforming shifts.
📉 Identifying Line Status with Andon Boards
In this final section, the speaker highlights another type of Andon system where the status of various production lines is displayed. The board shows details such as line 1 running smoothly, line 2 jammed, line 3 running, and line 4 needing material. This visualization helps the team quickly grasp the health of different lines and respond accordingly to maintain productivity.
Mindmap
Keywords
💡Andon
💡Green Light
💡Amber Light
💡Red Light
💡Production Line
💡Line Balancing
💡Process Engineer
💡Andon Board
💡Shift Target
💡PLC (Programmable Logic Controller)
Highlights
Andon is essentially a signal or alerting tool used in production lines.
An Andon system helps identify problems by signaling the status of a production line.
Andon signals can take the form of light systems (green, amber, red) or Andon boards.
A green light on the Andon system means the line is running smoothly without issues.
An amber (yellow) light indicates the line is paused or on hold due to an operator input or sensor.
A red light suggests a larger issue, possibly shutting down or halting the line.
Andon signals can be connected to PLCs, databases, or computers, allowing remote monitoring.
Process engineers can track the production line’s status remotely using Andon-connected systems.
Andon boards provide data on production line performance and highlight potential issues.
An example of an Andon board shows shift targets and actual production results, helping managers identify issues in production performance.
In one example, two shifts met their production targets, while the night shift (10 PM - 6 AM) fell short, indicating a problem during that period.
Andon systems trigger questions for management to resolve issues when targets aren’t met.
Another type of Andon board shows the status of different lines: running, jammed, or needing material.
Andon systems provide real-time feedback on production line health, improving operational efficiency.
The use of Andon systems is integral to identifying, notifying, and addressing production line issues efficiently.
Transcripts
so today's lesson is going to be about
andon and what an andon system is uh
andon is essentially just a signal or
alerting tool so it can take the uh form
of a light system that you see here
which you see a green Amber and red
light uh or it can be an andon board uh
and I'll show you some examples of that
as well essentially what it does uh it
it helps identify problems so when you
look at this line This appears to be a
production line uh and packaging line
where a product comes down the conveyor
here into a packaging area where the
product is boxed up and then moves out
into a loading area so at least that's
what it appears to be maybe it runs in
the other direction here I can't really
tell uh but the product is then
palletized and then moved on well you
can see if you look closely uh there are
some andon signals all around here and
we'll highlight those but what the andon
system does it helps identify problems
tells you about the health of the line
uh in this case if it's a green light it
means it's running well it's healthy
there's no problems on the line if that
light was to turn to the Amber or the
yellow um that would typically mean that
uh it's on hold or it's been paused
either by operator input or a uh sensor
has stopped the line temporarily maybe
it has something to do with line
balancing uh and it's temporarily halted
production on one of these lines because
it's over capacity uh and then it waits
for the other end to clear up before it
moves on uh if it's red that's typically
indicative of a uh larger problem and
the line may be shut down completely or
uh it may be uh stopped or turned off um
but the andon system which would be this
light as a part of the signal system
also helps notify people whenever these
kind of issues in a production line uh
happen uh these signals can also be tied
to plc's databases or computers and the
benefit with that is you can work
remotely and have this information at
your hand at any time so if I'm say a
process engineer in charge of this
production area I could be in another
location in an office or somewhere in a
different uh different area outside of
this area here and I could be signal via
a computer uh program of some sort that
will let me know uh the status of that
production line whether or not it is uh
working properly um to show you a little
bit closer uh in this case here these
andon lights I've circled them here
highlighted in the red circles these are
just a few of the andon signals that you
see built into this line and it doesn't
mean it's the only ones um andon uh are
actually a term referring to a system to
notify people so uh the the idea is to
incorporate these signal lights uh into
a workstation that could potentially
have a problem another way to look at
this is via uh an andon board and I've
got some examples here just from doing a
simple Google search and we'll slide
that over so you can see it but in this
case
here uh there are these are andon boards
so these are some examples of andon
boards that give you different types of
information usually related to the
health of a production line so if we
look at this one here real quick we see
that the shift Target is 625 units
whatever that unit is whatever it is
that they're building um 62 shift has
654 2 to 10 shift has
629 and 10 to 6 shift has 593 so you can
see that uh the first one and the second
one here have hit their targets uh going
above the shift Target but there's been
a problem on the 10 to 6 shift I'm
assuming this is time uh probably 10:
p.m. to 6:00 a.m. shift showing that on
that what I've referred to as uh third
shift or night shift uh that would be
593 pieces and for some reason they were
unable to hit their total Target so this
is an indication for management to say
okay we've got a problem on our third
shift something happened the night
before and that can that is what can
trigger the questions that need to be
asked uh to find out how to fix that
problem whatever it may be um another
indicator here this is another type of
andon system just showing line one uh
running line two jammed line three
running line four needs material so it's
just a different way of showing the same
information uh based on the health of
the line
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