What is the Value of Andon Boards in Lean Manufacturing?

Key Takeaways

• An Andon board is a Lean Manufacturing tool that makes problems visible in real time.
• Benefits include reduced downtime, better quality, faster decisions, and empowered operators.
• Andon boards can be a combination of stack lights, digital displays, MES dashboards, and mobile alerts.
• Industries from automotive to food & beverage rely on Andon for quick problem-solving.
• The greatest value comes when Andon is part of a larger MES strategy, enabling data-driven decision-making.

What is an Andon Board?

An Andon board is a visual management tool used in Lean Manufacturing to highlight problems on the production floor. It alerts operators, supervisors, and managers when something needs attention, such as a machine stoppage, a quality issue, or a production delay.

Originally, Andon was as simple as a stack light that turned red when a machine failed. Today, modern Andon boards are MES-integrated displays, dashboards, and mobile alerts that provide real-time visibility into production.

The purpose of an Andon board is simple: it makes problems easily visible in real-time so they can be fixed quickly.

What are the Benefits of an Andon Board?

Andon boards provide measurable benefits when used in Lean Manufacturing, including:

• Reduced Downtime: Alerts allow maintenance and support teams to act fast, minimizing lost production time.
• Improved Product Quality: Defects are flagged immediately, stopping flawed products from moving downstream.
• Faster Decision-Making: Real-time visibility helps supervisors reallocate resources and adjust schedules instantly.
• Empowered Workforce: Operators gain the authority to stop or flag problems without waiting for management approval.
• Better Communication: Everyone sees the same status, reducing confusion across shifts and departments.
• Data for Continuous Improvement: Integrated Andon data can be analyzed for root cause, not just symptoms.
• Higher Productivity: Fewer stoppages and quicker recovery times keep production lines moving.
• Cultural Benefits: Transparency reinforces teamwork and supports lean manufacturing goals that focus on continuous improvement.

What are the Features of Andon Boards in Manufacturing?

• Digital Display Boards: Large LED screens showing live production targets, downtime alerts, and efficiency metrics.
• Signal Light Towers: Simple red, yellow, and green stack lights that indicate machine status.
• MES-Integrated Dashboards: Advanced Andon boards linked to MES systems for real-time OEE, downtime, and maintenance tracking.
• Mobile Andon Alerts: Notifications pushed to tablets or smartphones so managers can respond instantly.

How Do Different Industries Use Andon Boards?

Andon systems are adaptable across industries. Each case shows how Andon evolves from a simple alert system into a strategic tool for visibility and performance. A few real-world applications include:

• Automotive & EV Manufacturing: At Lucid Motors, Andon integrated with MES to provide real-time visibility into assembly processes, reducing downtime and supporting production goals.
• Food & Beverage: Line operators use Andon towers to quickly flag stoppages caused by packaging, filling, or quality issues.
• Hydrogen Fuel Cell Manufacturing: MES-connected Andon boards deliver performance data, supporting efficiency and precision in complex assembly.

Why is Andon a Valuable Part of an MES Strategy?

On its own, an Andon board is effective. But when integrated into a Manufacturing Execution System (MES), it becomes far more powerful, transforming Andon from a reaction tool into a driver of proactive improvement.

• Event Tracking: Every alert is logged, creating data for root cause analysis and reporting.
• OEE Reporting: Downtime and performance data automatically flow into dashboards.
• Predictive Maintenance: Recurring Andon signals can highlight problems before they cause major failures.
• Unified Visibility: Operators, engineers, and managers see the same live information, improving alignment.

Andon – More Than Just Signals

The value of an Andon board lies in its ability to make problems visible, empower operators, and keep production flowing. When used in conjunction with MES, its impact grows even greater, turning every alert into actionable data that drives continuous improvement. For manufacturers pursuing digital transformation, Andon boards are more than signals, they are strategic tools for resilience, efficiency, and growth.

See how Andon boards fit into your digital transformation strategy. Contact NeoMatrix to get started.