Complex, digital, efficient. Or: production of today. Sources of error are manifold, but toxic effects can often be avoided or limited with suitable visualisation according to the Andon principle.
A malfunction on a producing machine, the packaging or removal of the end product falters, the follow-up order is not entered, the raw material does not arrive, the output or the quality collapses. In an industrial environment that - keyword digitalisation and Industry 4.0 - is increasingly trimmed to efficiency, disruptions in the process must be quickly registered and communicated. Continuous monitoring of running processes registers disruptions or deviations in real time. In order for workers and managers to be able to take countermeasures in time, there also needs to be a fast flow of information that can be viewed at any time.
Modern display technology optimises flow along the production chain
As a component of lean management, Andon provides usable information about the workflow along the entire production chain. Ultimately, Andon is nothing more than a visual tool for visualising productivity. The idea is not new: the so-called Andon boards were already introduced by Toyota in the 1960s as a descriptive process monitoring tool for relevant key figures and for the continuous improvement of production. However, the possibilities of modern display technology are constantly expanding and optimising their use. If current process performance is communicated in a way that is permanently visible to all employees, for example with the help of one or more large-area illuminated displays on the wall or ceiling of the production area, disruptions in the process can be dealt with immediately. Bright, large-format LED displays provide all employees with a quick overview of the current processes in their production environment - indispensable in a networked industry, in the era of digitalised work instructions and processes.
Process-relevant key figures in the sense of continuous improvement.
In this way, Andon provides an impulse for the continuous improvement of operational processes and supports the optimal interaction between man and machine. Efficiency, speed and reliability are the production-specific focus of Andon. When visualising information, Andon should always concentrate on those core figures that are
a) relevant for an efficient process and/or
b) subject to fluctuations or uncertainties.
Key figures that have no influence on production processes need not and should not be communicated. This prevents complexity in the visual recording and processing of information, and also ensures a targeted concentration on process-relevant key figures. Key figures that never reach a critical value for production or for which there is no dependency within production do not take up space on Andon boards.
Process-relevant can be:
- Productivity in terms of the number of units produced,
- Capacity in terms of optimal utilisation of production machines/lines,
- quality or error rate,
- disruptions,
- resources in terms of available raw material, employees or technology,
- all KPIs.
The appropriate KPIs result individually according to industry, product, internal control and production process.
LED predestined as technical solution for seamless Andon visualisation
LED technology offers the best conditions for making information "shine" prominently and visibly, even in large production halls. Strong colours meet high contrasts and thus provide the best reading conditions. Even in backlighting, dust or outdoors, light-emitting diodes impress with their flawless function and visibility. A modular design and customised adaptations make the best possible use of Andon's potential in production. Problem-free 24/7 continuous operation and freedom from maintenance create the prerequisites for continuous, seamless Andon visualisation. To support the visual output, it is also possible to connect acoustic signal transmitters, for example in the event of acute malfunctions, hazards or extreme process developments. Variable character heights as well as multicolouring structure the view and enable a quick, efficient glance. Double-sided displays as well as display units that visualise on three, four or more pages reach even the most remote workstation.
