What is Andon and Why It Matters

In manufacturing environments where speed, precision, and consistency are everything, small issues can snowball into big problems. Andon is a powerful visual management tool designed to prevent that.

Originating from the Toyota Production System, the word “Andon” means “paper lantern” in Japanese — a fitting metaphor for a tool that illuminates problems as they happen. In practice, it refers to a signaling system that provides real-time status updates on the production floor using lights, sounds, or digital boards.

But Andon is more than just a signal light. It’s a frontline empowerment mechanism. When an operator spots a problem, they can pull a cord or press a button, triggering a visual or audio alert. This stops the line or signals for assistance, allowing teams to address the root cause quickly.

The Colours of Clarity

The power of Andon lies in its simplicity. Through universal color coding, it allows anyone — from operators to supervisors — to instantly grasp the status of a workstation.

  • Green means normal operation.
  • Yellow signals that assistance is needed.
  • Red indicates production has stopped due to an issue.

These visual cues are easy to implement and instantly recognizable. When paired with proper escalation protocols, they allow for immediate response, reducing delays and preventing defects from flowing downstream.

This kind of real-time feedback creates a loop of continuous improvement. Problems are no longer hidden or delayed until a quality check. Instead, they’re addressed at the source, in the moment.

Implementing Andon in Your Operations

Successful Andon deployment doesn’t require complex technology, but it does require clarity and commitment. Here are three key steps to ensure a smooth rollout:

  1. Identify Critical Points: Focus on areas where issues often occur — bottlenecks, high-defect zones, or stations with manual processes.
  2. Install Appropriate Signaling Devices: This can range from simple stack lights to digital dashboards. Keep it consistent and easy to interpret.
  3. Train and Empower Teams: Make sure employees understand when and how to use the system — and just as importantly, that they are supported when they do.

When done right, Andon enhances accountability and builds trust. Workers don’t fear raising a flag because they know the system supports improvement, not punishment.

The Benefits of Making Problems Visible

Visual management is a core principle in Lean, and Andon is its most dynamic expression. When production teams can see what’s happening — good or bad — they’re better equipped to take action. The benefits are clear:

  • Reduced Downtime: Problems are fixed faster, minimizing line stoppages.
  • Improved Product Quality: Defects are caught early, not after full production.
  • Enhanced Communication: Everyone on the floor shares the same real-time data.

In a world where manufacturing success depends on agility and consistency, Andon provides the clarity teams need to perform at their best.

Don’t let hidden problems undermine your operations. Illuminate them with Andon — and empower your people to act when it matters most.