{"id":1688,"date":"2020-07-02T13:35:45","date_gmt":"2020-07-02T13:35:45","guid":{"rendered":"http:\/\/localhost:10003\/lexicon-terms\/andon\/"},"modified":"2022-05-20T16:59:33","modified_gmt":"2022-05-20T20:59:33","slug":"andon","status":"publish","type":"glossary","link":"https:\/\/www.lean.org\/lexicon-terms\/andon\/","title":{"rendered":"Andon"},"content":{"rendered":"<p>Andon is a visual management tool that highlights the status of operations in an area at a single glance and that signals whenever an abnormality occurs.<\/p>\n<p>An andon can indicate:<\/p>\n<ul>\n<li>production status \u2014 for example, which machines are operating<\/li>\n<li>an abnormality \u2014 for example, machine downtime, a quality problem, tooling faults, operator delays, and materials shortages),<\/li>\n<li>needed actions, such as changeovers.<\/li>\n<\/ul>\n<p>Organizations can also use andon to display the status of production in terms of the number of units planned versus actual output.<\/p>\n<p>A typical andon, which is the Japanese term for &#8220;lamp,&#8221; is an overhead signboard with rows of numbers corresponding to workstations or machines. A number lights when either:<\/p>\n<ul>\n<li>a machine sensor detects a problem, which automatically trips the appropriate light or<\/li>\n<li>an operator pulls a cord or pushes a button.<\/li>\n<\/ul>\n<p>The illuminated number summons a quick response from the team leader. Colored lighting on top of machines to signal problems (red) or normal operations (green) is another type of andon.<\/p>\n\n\n<div class=\"wp-block-image\"><figure class=\"aligncenter size-large is-resized\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/www.lean.org\/wp-content\/uploads\/2021\/01\/andon-leaper.svg\" alt=\"Team member pulling an andon\" class=\"wp-image-9981\" width=\"482\" height=\"458\"\/><\/figure><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Andon and Fixed-Position Stop<\/h2>\n\n\n\n<p>The fixed-position stop system that Toyota uses in its final-assembly lines is very famous and very effective. Whenever an operator encounters any problem, he or she pulls a rope, which will cause the production line to stop, not immediately, but after the product reaches a predetermined position. Efforts are made to bring the line back into normal operation by solving the problem immediately, but if the problem stays unsolved within the cycle, the conveyor stops at the fixed position.<\/p>\n\n\n\n<p>If the operation having a problem could stop at any position, the work of every other operation would be interrupted. Consequently, this might cause operator error, such as incorrect assembly. Instead, stopping at the fixed position (i.e., the end of each workstation) will not negatively affect other workstation operations in safety and quality. With this method, stoppage time is minimized yet the jidoka concept is maintained because abnormalities are remedied and defects never passed on.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"935\" height=\"1024\" src=\"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Fixed-Position-Stop_Andon-935x1024.png\" alt=\"\" class=\"wp-image-20687\" srcset=\"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Fixed-Position-Stop_Andon-935x1024.png 935w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Fixed-Position-Stop_Andon-274x300.png 274w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Fixed-Position-Stop_Andon-768x841.png 768w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Fixed-Position-Stop_Andon-150x164.png 150w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Fixed-Position-Stop_Andon-375x411.png 375w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Fixed-Position-Stop_Andon-190x208.png 190w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Fixed-Position-Stop_Andon-600x657.png 600w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Fixed-Position-Stop_Andon.png 1116w\" sizes=\"(max-width: 935px) 100vw, 935px\" \/><\/figure>\n\n\n\n<div style=\"height:100px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-image\"><figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"600\" height=\"300\" src=\"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/03\/download-standardized-work-pdf.jpg\" alt=\"\" class=\"wp-image-19368\" srcset=\"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/03\/download-standardized-work-pdf.jpg 600w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/03\/download-standardized-work-pdf-300x150.jpg 300w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/03\/download-standardized-work-pdf-150x75.jpg 150w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/03\/download-standardized-work-pdf-375x188.jpg 375w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/03\/download-standardized-work-pdf-190x95.jpg 190w\" sizes=\"(max-width: 600px) 100vw, 600px\" \/><\/figure><\/div>\n\n\n\n<div style=\"height:100px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">100 Years of Innovation in the Work: an Explanation of Fixed-Position Stop and Andon<\/h2>\n\n\n\n<figure class=\"wp-block-embed aligncenter is-type-video is-provider-youtube wp-block-embed-youtube wp-embed-aspect-16-9 wp-has-aspect-ratio\"><div class=\"wp-block-embed__wrapper\">\n<iframe loading=\"lazy\" title=\"Highlighting 100 Years of Innovation in the Work\" width=\"500\" height=\"281\" src=\"https:\/\/www.youtube.com\/embed\/4ZLaBl4Y0qM?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe>\n<\/div><\/figure>\n\n\n\n<div style=\"height:100px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Additional Resources<\/h2>\n\n\n\n<div style=\"height:29px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-media-text alignwide is-stacked-on-mobile\" style=\"grid-template-columns:35% auto\"><figure class=\"wp-block-media-text__media\"><img loading=\"lazy\" decoding=\"async\" width=\"232\" height=\"221\" src=\"https:\/\/www.lean.org\/wp-content\/uploads\/2021\/01\/andon-leaper.svg\" alt=\"Team member pulling an andon\" class=\"wp-image-9981 size-full\"\/><\/figure><div class=\"wp-block-media-text__content\">\n<h4 class=\"wp-block-heading\">Article<\/h4>\n\n\n\n<h3 class=\"wp-block-heading\"><a href=\"https:\/\/www.lean.org\/the-lean-post\/articles\/gemba-and-quality\/\">Gemba and Quality<\/a><\/h3>\n<\/div><\/div>\n\n\n\n<div style=\"height:36px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-media-text alignwide is-stacked-on-mobile\" style=\"grid-template-columns:35% auto\"><figure class=\"wp-block-media-text__media\"><img loading=\"lazy\" decoding=\"async\" width=\"386\" height=\"267\" src=\"https:\/\/www.lean.org\/wp-content\/uploads\/2021\/01\/andon-workstation-3.png\" alt=\"Operator pulling andon and team leader responding\" class=\"wp-image-9763 size-full\" srcset=\"https:\/\/www.lean.org\/wp-content\/uploads\/2021\/01\/andon-workstation-3.png 386w, https:\/\/www.lean.org\/wp-content\/uploads\/2021\/01\/andon-workstation-3-190x131.png 190w, https:\/\/www.lean.org\/wp-content\/uploads\/2021\/01\/andon-workstation-3-150x104.png 150w, https:\/\/www.lean.org\/wp-content\/uploads\/2021\/01\/andon-workstation-3-300x208.png 300w, https:\/\/www.lean.org\/wp-content\/uploads\/2021\/01\/andon-workstation-3-375x259.png 375w\" sizes=\"(max-width: 386px) 100vw, 386px\" \/><\/figure><div class=\"wp-block-media-text__content\">\n<h4 class=\"wp-block-heading\">Article<\/h4>\n\n\n\n<h3 class=\"wp-block-heading\"><a href=\"https:\/\/www.lean.org\/the-lean-post\/articles\/were-installing-an-andon-system-what-should-we-expect\/\" target=\"_blank\" rel=\"noreferrer noopener\">We\u2019re installing an andon system \u2013 what should we expect?<\/a><\/h3>\n<\/div><\/div>\n\n\n\n<div style=\"height:36px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-media-text alignwide is-stacked-on-mobile\" style=\"grid-template-columns:35% auto\"><figure class=\"wp-block-media-text__media\"><img loading=\"lazy\" decoding=\"async\" width=\"820\" height=\"640\" src=\"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Andon_1.jpg\" alt=\"An operator wondering if he should place a form on a red square to indicate there is a problem requiring help.\" class=\"wp-image-20688 size-full\" srcset=\"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Andon_1.jpg 820w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Andon_1-300x234.jpg 300w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Andon_1-768x599.jpg 768w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Andon_1-150x117.jpg 150w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Andon_1-375x293.jpg 375w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Andon_1-190x148.jpg 190w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Andon_1-600x468.jpg 600w\" sizes=\"(max-width: 820px) 100vw, 820px\" \/><\/figure><div class=\"wp-block-media-text__content\">\n<h4 class=\"wp-block-heading\">Article<\/h4>\n\n\n\n<h3 class=\"wp-block-heading\"><a href=\"https:\/\/planet-lean.com\/5s-office\/\" target=\"_blank\" rel=\"noreferrer noopener\">Andon Squares \u2014 5S in the Office<\/a><\/h3>\n<\/div><\/div>\n\n\n\n<p><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Andon is a visual management tool that highlights the status of operations in an area at a single glance and that signals whenever an abnormality occurs. An andon can indicate: production status \u2014 for example, which machines are operating an abnormality \u2014 for example, machine downtime, a quality problem, tooling faults, operator delays, and materials [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":1992,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"_acf_changed":false,"_relevanssi_hide_post":"","_relevanssi_hide_content":"","_relevanssi_pin_for_all":"","_relevanssi_pin_keywords":"","_relevanssi_unpin_keywords":"","_relevanssi_related_keywords":"","_relevanssi_related_include_ids":"","_relevanssi_related_exclude_ids":"","_relevanssi_related_no_append":"","_relevanssi_related_not_related":"","_relevanssi_related_posts":"6778,6973,8962,6939,4911,4199","_relevanssi_noindex_reason":"","footnotes":""},"glossary-categories":[],"glossary-tags":[],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v22.9 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Andon - What Is It? 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