Fabled andon cord, symbol of Toyota Way

In 2014, Toyota retired the Andon pull-cord system, a symbol for the lean, efficient and quality manufacturing in the Toyota Way, which has been replicated around the world in the automotive industry and other manufacturing industries.

The Andon pull-cord is the first concept in Toyota’s Andon solution, which uses a pull cords system at arm’s reach. When problems occur, worker will pull the cord to call support instead of yelling. Team leader will be come to help troubleshooting, and may stop the line if the problem is not resolved immediately

The application of this solution has get about remarkable efficiency in manufacturing at the factories of Toyota and has been replicated in manufacturing of all industries. However, the use of hanging cords will affect the beauty as well as convenience, standardize at the factories. This will also affect the efficiency as well as the barrier for 5S application at the factories. So, the pull cords system has been replaced by a new solution, the buttons.

The push buttons are located at points at the waist-high of workers with the criterion “easy reach of workers”. Operational principles and working scripts do not change, but it improves aesthetics, neatness. The final goal of this change is to eliminate overhead clutter, create a more comfortable and safer work environment.

Simultaneously with the removal of the pull cords system, the current technology allows the deployment of “wireless andon” systems to ensure efficiency, neatness, quick execution, easy maintenance, cost savings , and more. Wireless solutions include using wifi network or radio communications with Zigbee technology.

All improvements in the factory and factory are geared towards efficiency, productivity, quality and safety. Andon is an essential solution in the process of this improvement.