Andon Systems and OEE improvement
January 14, 2009 by david.evanson
What are Andon systems or Andon lamps?
Andon lamps are an extremely simple system of visual management for helping teams identify when there is a problem with a process or machine. Originally they were developed as part of the Jidoka quality-control method within the Toyota Production System and have now been incorporated into standard lean manufacturing practice
Originally andon lamps were used to notify teams of a quality problem, and more frequently we see them installed on continuous flow lines to help inform operators of why machines have stopped. For example if i have an operator running two packaging machines and one of the machines stop, a simple Andon light stack can instantly tell the operator if he has a problem (and has to intervene) or if the machine has just run out of product.
Here are some sample Andon Systems courtesy of google images:
Andon lamp block
A traditional andon light stack
Andon panel with fault alarms
Andon Text display
Benefits of traditional Andon systems in your visual factory:
- Reduce reaction times for machine problems - operators see the state of machines quickly
- Reduced downtime for fault fixing - lamps indicate most common “faults” e.g. low reel, jams etc
- Improve management efficiency - Managers can quickly see which machines are stopped on a busy floor
Drawbacks of traditional Andon systems in your lean implementation:
- Signals need to be interpreted - complex systems need a code or key card to help operators remember what the alarms mean.
- Can be hard to see - if they’ve been in place for a long time lights often get damaged and dirty and can be hard to see. They can also often become ‘background noise’.
Taking Andon systems to the next level…XL800 for the ultimate visual factory
The XL800 OEE system brings Andon systems into the 21st century by taking all the strengths of existing systems, adding even more functionality, whilst keeping the core simplicity.
When you install an XL800 OEE System on your machine or line the highly visual alphanumeric display system can be used to highlight KPI’s and running conditions just like any display system.
Basic functionality:
Almost instantly the XL800 OEE system can support your lean manufacturing implementation by very quickly enabling you to show:
- MACHINE DOWN + Duration of downtime
- BREAK TIME REMAINING + Duration of break
- CHANGEOVER + Duration of changeover
More advanced functionality:
If you can get a signal from your machine to indicate why that machine has stopped then your XL800 could automatically display additional faults or alarms such as:
- Stop - Build Back (too much product on outfeed)
- Stop - Lack (no raw materials on infeed)
- Stop - No raw material
- Stop - Guards open
- Quality check due now (based on the number parts produced)
- Stop - SPECIFIC FAULT MESSAGE
- Target achieved - Good job team
- …..and the list goes on! If you can get us a signal, the XL800 OEE System can give you a display!
So what are the benefits of an XL800 as your Andon system?
- All of the benefits as traditional Andon systems
- Inform and motivate your team: by displaying real time data for how long each alarm has been triggered, and by showing targets for the production run
- Increase productivity: Simplify your shop floor - the display is 100% user configurable so you can quickly select the alarms that make the most difference to you
- Save money: Your operators will be able to respond to the right causes of machine downtime and get your machines fixed faster.
- Increase OEE: With machines being fixed faster you will produce more product than ever before
- Essential for TPM: The built in reporting and analytics software in the XL800 system is ideal for driving your TPM implementation as part of your lean journey.
Protected: Realising Leadership Potential (RLP)
December 17, 2008 by samirshah
Displaying Key Performance Indicators (KPIs)
November 5, 2008 by samirshah
Every company has some metrics to measure how well they are performing against targets. A few get these measures correct. The idea is to measure The Key Metrics so as to not over complicate and dilute the absolute key indicators for success.
Imagine driving a car….the dashboard provides me with key indicators to show how it is performing. There are some indicators that I react to immediately and others that warn me so I can plan ahead. To give an example of this:
- Immediate Reaction - If the speed indicator shows that the current speed is above the legal limit there will be an instant reaction to reduce that speed
- Planned intervention - If the fuel dial shows that there is a quarter tank left, I would make sure that I fill up at the next available opportunity
Now imagine if I received this feedback daily or weekly? It will be too late before I realise I need to do something and will be likely to receive a speeding ticket or left stranded as there was no fuel left. This is how most companies measure their Key Performance indicators. It is too late to remedy what happened yesterday. Won’t it be immensely beneficial to indicate the current performance to target in real time?
The XL800 system enables you to give this instantaneous feedback on the level of performance to the people who are driving your production. They can use this information to make an immediate change or a planned intervention at their earliest convenience. The important thing is that they are given the information to enable them to make a certain decision.
You can customise your XL800 system to display whatever performance measures you deem are important. It is capable of measuring over 100KPIs and this gives you the flexibility to customise and display your chosen KPIs to ensure that you are tracking the measures that will ensure your ultimate success!
Follow this link to get more information on defining the right KPIs for you http://en.wikipedia.org/wiki/Key_performance_indicator
