Andon system calls for support, monitors production and optimizes waste

For large-scale manufacturing factories with a lot of workers, maintaining communication and updating information is very difficult in traditional ways. Moreover, professional support staff such as maintenance, engineering, quality ... need to be streamlined, so they must be flexible and handle incidents at the right place, at the right time. So which scenario for a problem occurs?

Imagine, in a large factory, Worker A at position 8 of line 05 has a machine problem, the sequence of steps will happen in the following scenario:

• Worker pre-inspection takes about 1 minute according to routine.
• After that, the worker decides to call for help from the supervisor. How to notify the supervisor? Need to call or find the captain is going somewhere takes about 30 seconds, and then 30 seconds, the captain is present.
• When the leader arrives, they exchange for about 30 seconds, consider together for 1 minute.
• Since the captain cannot handle it on his own, call assistance from the Service. After calling, searching and connecting, it takes 3 minutes for maintenance staff to reach the problem location.
• Complete maintenance and restarting after 6 minutes

Total time the machine stops is 12 minutes 30 seconds. It is a terrible waste of time, making tens to hundreds of products or semi-finished products. In the large scale of the factory, these incidents happen regularly, at any location, line, and with any worker. Therefore, the level of waste caused by production stops (Downtime) is very large.

So how to gradually reduce this waste? IAndon Call’s solution is the answer!

The iAndon Call system includes buttons at the worker’s position, accompanied by a tower light or signal light to show. The number of buttons and light tower floor respectively depends on the characteristics of the content to be announced or each specific industry, for example:

• Report machine failure -> Call Service [RED – RED]
• Report shortage of raw materials -> Call Supplies, Logistics [YELLOW – YELLOW]
• Quality Issues -> Call Quality Control [BLUE – BLUE]
• Technical issue or other issue -> Call Team Leader [GREEN – GREEN]
• …

Each problem will be specified by a specific color for easy identification.

When the worker presses the button at the position, the corresponding light will flash and there may be a buzzer to increase attractiveness. At the same time, the Andon screen will receive information to show problems, location occurring in large numbers and a visual color palette. From there, the relevant departments will approach and assist in solving the problem, minimizing downtime due to the problem, solving problems early and reducing problems that can cause failure to lead to the next operation.

Andon software system also logs problems, call initiation time, access support time and problem end time, forms a detailed log system, helps evaluate and assigns analysis to improve production operations, improve efficiency, quality, enhance interactivity and continuously update, as soon as any stage is needed, without wasting resources just in time. .

The system is usually deployed by wireless technology, making deployment quick, economical and easy to maintain. Avani is a professional Andon supplier, with experience in deployment and technology capacity, we will help factory solve problems related to andon system, monitor automatic production to build a system. detailed, multidimensional information, geared towards smarter and more efficient production activities.