Andon System for the Real Time quality control
Andon is a part of the Toyota Production System (TPS) which notifies quality and process problems. It is used for real-time defect detection and prevention.
For the implementation of the Andon system, one screen is provided to the quality checker. (As Shown in the below Picture)
So, the quality checker clicks on the various tabs as per the quality of the product. If the quality of the product is good, he will click on the pass tab otherwise the checker will click on the respective tab.
Every defect is connected to its respective station where the defects are generated and for every defect there is a permissible limit defined. One Andon Tower light is installed at each station for the indication of the quality performance of that station.
When the defects of any station are within the permissible limit, the Andon Light of the station will change to a green light.
As soon as defects cross the first permissible limit the light of the Andon Tower will change from green light to orange light. This helps bring awareness to the workers and the line in-charge will know that the station is generating the defect. The line in-charge will then make frequent visits to that station for the reduction of defect generation.
If the defects cross the second permissible limit the light of the Andon Tower will change to red light. This will inform the line in-charge and workers that this station is generating lots of defects. This will bring the line in-charge at the station till the defect issue gets resolved.
Ref. – Liker, Jeffrey (2004) “The Toyota Way” New York:McGraw Hill ISBN 0-07-139231-9