Andon (Process Control Board)

1. Andon(Process Control Board)

2. Andon Japanese translation: Lantern What is Andon ? • A visual control that enables the operator to inform the Team Leader (or responsible line cover) that an abnormal condition exists. Note: IT IS NOT A TOOL TO STOP THE LINE, IT IS IN FACT A TOOL TO KEEP THE LINE RUNNING

3. Andon Vehicle Flow PLAN 153 PROD 146 LINE 1 DOWN 021 12:05 1 2 3 4 5 6 HELP PRE PST EQUIP QUALITY SYSTEM HEALTHY 10% 30% 50% 70% 90% L10 L10 L10 L10 Process Control Overview ONE TOUCH FIRST TIME EVERY TIME ONE TOUCH FIRST TIME EVERY TIME ONE TOUCH FIRST TIME EVERY TIME ONE TOUCH FIRST TIME EVERY TIME

4. Andon • Is activated by : • the process operator manually • automatically by links to equipment • Provides real time information. • Trigger for problem solving. • Prevents concerns being passed onto the next process ie Supports JIDOKA • Key driver towards Lean Manufacturing.

5. TO ALERT LEADER • PULL IF QUALITY OR SAFETY ISSUE • PULL TO ALERT T/L OF ANY ABNORMALITY • STOP- CALL- WAIT PULL THE CORD

6. EFFECT of PULLING CORD PROBLEM INDICATION RESPONSE

7. Andon • Simple to read. • Information easy to understand at a glance. • Prominent location for the line support to see. PLAN 153 PROD 146 LINE 1 DOWN 021 12:05 • Shows location of the concern, not detail. 1 2 3 4 5 6 HELP PRE PST EQUIP QUALITY SYSTEM HEALTHY What does it look like ?

8. Andon PLAN 153 PROD 146 LINE 1 DOWN 021 12:05 1 2 3 4 5 6 HELP PRE PST EQUIP QUALITY SYSTEM HEALTHY Hardware overview: Pull cords and beacons

9. Andon How does it work ? Line running PLAN 153 PROD 146 LINE 1 DOWN 021 12:05 1 2 3 4 5 6 ATTEND HELP PRE PST EQUIP CRD QUALITY P SYSTEM HEALTHY

10. Andon PLAN 153 PROD 146 LINE 1 DOWN 021 12:05 1 2 3 4 5 6 HELP PRE PST EQUIP QUALITY SYSTEM HEALTHY How does it work ? Concern - Cord Pulled Pull cords and beacons

11. Andon How does it work ? Relevant position lights up PLAN 153 PROD 146 LINE 1 DOWN 021 12:05 1 2 3 4 5 6 ATTEND HELP PRE PST EQUIP CRD QUALITY P SYSTEM HEALTHY

12. Andon Marquee PLAN 153 PROD 146 LINE 1 DOWN 021 12:05 1 2 3 4 5 6 HELP PRE PST The marquee shows the following information: EQUIP QUALITY SYSTEM HEALTHY System healthy Production Held Information System fault Information Emergency Stop information Buffer warning levels Maintenance Call Information

13. Andon The purpose of the chimes is to alert the personnel in that area that there has been a change in status on either the line side equipment or on the local Andon board. Every team on the line is allocated a sounder. Each sounder has the ability to sound individual chimes. Every line is usually allocated two chimes: 1st chime is for the purpose of warning the local team. 2nd chime is for the purpose warning the whole line. Chimes

14. Andon Effective use of an Andon system relies upon the introduction of de-coupled production lines with managed buffers. De-coupled lines allow production areas to stop without immediate effect to following and preceding areas. It ensures that, within reason, a continuous flow of production is maintained by using the managed buffers between the lines. De-coupling and Managed Buffers.

15. Andon Total line stop Stn1 - Stn 60 Stn 1 Stn 60 Line stop Stn 1 Stn 20 Stn 41 Stn 60 Line stop Stn1-Stn20 Line stop Managed buffers Production continues until preceding buffer short Stn 21 Stn 40 De-coupling and Managed Buffers.

16. How big should the buffer be? How to manage the buffer? Set the buffer quantity based upon the line performance / downtime Reduce buffers as pulls & downtime reduce No of pulls 10 mins ~ 5 cars (depends on Takt) 1 2 5 20 3 10 Time in secs