What Are Andon Lights?
Andon lights are visual signaling devices that are used in manufacturing and industrial applications to indicate the status of a process, machine, or workstation.
They are an important part of lean manufacturing and began in the Toyota Production System, where "Andon" (a Japanese term meaning "paper lantern") refers to a system for alerting workers to issues that need attention.
These lights are typically part of a stack light or signal tower setup, using bright, color-coded lights and sometimes audible alarms to communicate real-time information clearly and quickly.
Purpose
Andon lights are an immediate, easy-to-understand communication tool in what are usually busy and noisy industrial settings. They can be used for:
- Status Indication:
- Status of a machine or process (e.g., running, stopped, or in error).
- Example: A green light might indicate normal operation, yellow for a warning or maintenance need, and red for a serious faultor equipment down.
- Error or Issue Alert:
- Equipment malfunctions, material shortages, or quality defects, alerting operators that action is needed
- Example: A red light with a buzzer might signal a machine breakdown, alerting workers to look into the issue.
- Lean Manufacturing Support:
- Support "Jidoka" (automation with a human touch), a lean principle where processes are stopped automatically, or manually, when issues are detected.
- Example: An operator pulls an Andon cord or presses a button to activate the Andon light, halting production until the issue is resolved.
- Encourages Teamwork:
- Assists communication across teams, especially in large facilities, by providing a clear visual cue that can be seen from a distance.
- Example: A flashing light might call a supervisor to a specific workstation.
Design and Components
Andon lights are typically part of a stack light or signal tower, which consists of multiple colored light modules stacked vertically. Here’s a breakdown of their key components:
- Light Modules:
- Colors: Common colors include red (stop/error), yellow/amber (warning/caution), green (normal operation), blue (maintenance or material request), and white (custom or neutral status).
- LED Technology: Modern Andon lights use LEDs for brightness, energy efficiency, and durability, replacing older incandescent bulbs.
- Modularity: Many systems are modular, allowing users to customize the number and arrangement of light segments (e.g., 1–5 tiers).
- Audible Alarms:
- Many Andon lights include buzzers or alarms for visibility in noisy environments.
- Example: A high-decibel buzzer might be used on a red light for immediate attention.
- Mounting Options:
- Andon lights can be pole-mounted, wall-mounted, or directly attached to machinery.
- Common in environments like assembly lines, warehouses, or CNC machine shops.
- Control Systems:
- Manual: Operators activate lights using buttons, switches, or Andon cords (e.g., pulling a cord to signal an issue).
- Automated: Integrated with PLCs (Programmable Logic Controllers), sensors, or IoT systems to trigger lights based on machine data.
- Wireless: Some modern systems use wireless technology for remote activation or monitoring, reducing wiring complexity.
- Durability Features:
- Built for industrial environments, Andon lights often have IP65 or higher ratings for dust and water resistance.
- Some are designed for harsh conditions, like high temperatures or hazardous areas (e.g., explosion-proof models).
How Andon Lights Work in Applications
Andon lights are usually used in the production process to improve efficiency and problem-solving. Here’s an example:
- Normal Operation: A green light is lit, indicating that a machine or process is running well.
- Issue Detected: If a problem occurs (a part defect or machine jam), an operator or sensor triggers the Andon system, switching the light to yellow or red.
- Alert and Response: The light (and possibly a buzzer) alerts workers or supervisors to the issue. In some systems, the production line stops automatically until the issue is addressed.
- Resolution: Once the problem is fixed, the light is reset to green, signaling that operations can begin again.
- Data Logging: In advanced setups, Andon systems log events for analysis, helping identify recurring issues and improve processes.
Common Applications
Andon lights are widely used across industries, particularly in:
- Manufacturing: To monitor assembly lines, detect defects, or signal material shortages.
- Automotive: Common in car manufacturing plants for real-time process control (e.g., Toyota’s production lines).
- Warehousing and Logistics: To indicate order-picking status or equipment issues.
- CNC and Machine Shops: To show machine status (e.g., running, idle, or fault).
- Smart Factories (Industry 4.0): Integrated with IoT systems for real-time data monitoring and remote alerts.
Benefits of Andon Lights
- Improved Communication: Clear, visual signals reduce miscommunication in fast-paced environments.
- Faster Problem Resolution: Immediate alerts minimize downtime by prompting quick responses.
- Enhanced Quality Control: Stopping processes for defects ensures high-quality output.
- Lean Efficiency: Supports lean principles by reducing waste and improving workflow transparency.
- Flexibility: Modular and customizable designs suit various applications and environments.
- Data Integration: Modern Andon systems provide data for analytics, aiding continuous improvement.
Also Referred To As ...
Industrial customers often use the following phrases when searching for Andon lights:
- Andon lights for manufacturing
- industrial Andon systems
- wireless Andon lights
- manual Andon stations
- LED Andon tower lights
- Andon lights with buzzer
- smart Andon systems for Industry 4.0
Marshall Wolf Automation is an industrial component distributor that handles multiple lines of stack lights and andon system components. We are also proudly independent and women-owned!