Andon Systems and OEE improvement
January 14, 2009 by adrianpask
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.
Help your operators create their own improvement toolkit
December 3, 2008 by adrianpask
I was asked today about which books i would recommend for getting more information on continuous improvement implementation in the FMCG industry. Specifically the guy i was talking to had already read The Toyota Way and The Goal, and instead wanted something really practical to help with a specific continuous improvement implementation, something that he could use with his front line managers.
So here is a range of books that i massively recommend (and often send copies to new clients considering SMED, 5s, TPM, OEE, Poka Yoke exercises). These books are written ‘for operators’ and are extremely practical, straight forward, and hugely valuable in any application:
All the links will send you to Amazon.co.uk:
2. Identifying waste on the shop floor
3. Mistake proofing for opeartors - Poke Yoke made really simple, a great book
4. Pull production for operators
8. Cellular Manufacturing for operators
10. Quick Changeover for operators (SMED)
Just remember that there’s a difference between knowing the tools and knowing how to apply them. These books make a great start of introducing topics in a way which makes implementing them just a little bit easier.
Reflections on 2 days at WTG Conference in Rotterdam
November 18, 2008 by adrianpask
Whilst i’m sat in Rotterdam airport reflecting on 2 days at the World Trade Group 7th Annual World Food Technology and Innovation conference (http://manufacturing.foodinnovate.com/) i thought it may be worth reflecting on some of the lessons/thoughts that have come to me from the past few days.
Over the last couple of days it’s been an absolute pleasure talking to a number of Food and Drink Manufacturers’ about the issues and opportunities that exist within their European operations. Specifically a number of themes came through for me:
1. Obviously without surprise product cost is an extremely high priortity across every sector. The majority of manufacturers are experiencing some downturn in business recenly but nothing anywhere as large as that affecting our colleauges in Automotive sectors.
2. A large number of businesses have started their own internal development programmes and a lot of people are talking about ‘lean’, ‘TPM’ and ‘Toyota’.
3. When exploring these strategies it would appear that most businesses are choosing to cherry-pick particular elements of these programmes for implementation in the site, rather than wholesale adaptation and adoption. The message i got here is that “we’re not Japanese automotive manufacturers so we have to pick what works for us”.
4. There is a broad recognition that data and good quality information is key to delivering these programmes. I had great pleasure in showing our XL800 system to a number of manufacturers as a means of collecting this data.
5. A lot of suppliers are talking about Energy Sustainability, but i didn’t hear this back from many of the manufacturers.
6. In the session hosted by ATS International we had a great discussion about people involvement in change programmes. Specifically the value of creating improvement pilots and ensuring that outcomes of these programmes are communicated. We also explored how expectations need to be managed if the desired outcome is sustainable results….people can get impatient when results aren’t immediate. The key message was still - talk to your teams, get their advice, filter with data, and act act act.
7. Teams need to be motivated to improve - a real burning platform creates real results.
8. The point above really re-inforces something that one of my mentors says is the secret to manufacturing improvement: “Doing simple things to an exceptionally high level”. Whilst many sessions debated the value of various lean tools, the message for me is a clear - just decide what you’re doing and get on with it!
9. Oh and everyone is measuring OEE!
A very interesting and enjoyable 2 days. My thanks to all those i met and shared ideas with me.
