Andon is a visual and/or audible alert system used in manufacturing to signal issues on the production line in real time. Connected worker technology enhances Andon systems by enabling faster issue detection, response, and resolution through real-time data sharing and mobile alerts.
Read this article to learn more about Andon:
Andon is a visual and/or audible alert system used in manufacturing environments to notify teams of issues on the production line. The term originates from the Japanese lean manufacturing principles of the Toyota Production System (TPS) and translates roughly to “sign” or “signal.”
An Andon system empowers frontline workers to signal problems such as equipment malfunctions, quality concerns, or supply shortages—triggering immediate responses and ensuring that production doesn’t suffer from extended downtime or cascading errors.
Manufacturers today face increased pressure to improve efficiency, reduce waste, and maintain high product quality. In this context, Andon systems provide real-time visibility and foster a culture of accountability and rapid problem resolution.
Andon systems have evolved from simple manual tools to complex digital platforms. Here’s a breakdown:
Traditional setups with pull cords, buttons, or indicator lights. Workers activate a signal when a problem is detected.
Modern solutions using mobile devices, dashboards, connected worker technology, and IoT sensors to automatically detect and report problems across connected machinery.
Large screens on the shop floor that display production metrics, issue alerts, and real-time updates.
Audible alerts such as buzzers or alarms that signal specific types of issues (e.g., quality vs. mechanical).
| Problem Type | Andon Trigger Example | Result |
|---|---|---|
| Equipment Breakdown | Operator presses a button when a machine jams | Maintenance is dispatched immediately |
| Quality Defect | A worker notices a flawed component | Quality team is alerted for inspection |
| Supply Shortage | Material bin runs low and sensor detects it | Replenishment team is notified |
| Process Deviation | A step is skipped in a digital work instruction | Digital Andon flags the workflow issue |
Andon is one of the most effective tools in the Lean Manufacturing toolbox, supporting principles such as:
While traditional Andon systems rely on manual input, Smart Andon systems are powered by AI, IoT, and connected worker technology, and integrate with digital workflows and automation platforms to:
Smart Andon systems are no longer just visual alerts—they’re intelligent, integrated tools that drive proactive decision-making and real-time problem resolution. And with Augmentir, you get more than alerts—you get insight, automation, and agility.
Augmentir’s connected worker platform enables real-time performance monitoring through integrated Andon functionality:
Augmentir is the only AI-powered connected worker platform that seamlessly integrates digital Andon functionality into broader operational workflows. Our platform goes beyond simple issue reporting to deliver a fully connected, data-rich experience that transforms how manufacturing teams respond to problems.
Here’s how Augmentir supercharges Andon capabilities:
Smart Andon is just one part of the bigger picture. Create a unified digital thread from frontline detection to enterprise-level insights with bi-directional integration into enterprise production systems. Augmentir integrates with:
Implementing a Smart Andon system with Augmentir means:
Schedule a demo today to see how Augmentir can transform your shop floor into a real-time, insight-driven, continuously improving environment.
To provide real-time alerts for production issues, enabling quick response and minimal disruption.
No. While it originated in automotive, Andon is used in electronics, food production, pharmaceuticals, and more.
Yes. IoT-enabled Andon systems detect issues automatically and trigger alerts without manual input.
