In fast-paced manufacturing environments, even a small delay can snowball into major inefficiencies. But what if frontline workers had the power to stop the line not to delay production, but to improve it?
That’s where the Andon system comes in.
Originally developed as part of Toyota’s Lean manufacturing system, Andon is not just a tool—it’s a symbol of empowerment, visual control, and respect for people. It brings to life the Lean principles of Jidoka and Kaizen by enabling operators to raise issues the moment they happen.
What is the Andon System?
Andon, literally meaning "paper lantern", refers to a real-time alert mechanism used in manufacturing to indicate a problem with production. It’s a visual and/or audio signal—like lights, buzzers, or digital displays—used to:
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Alert team members of abnormalities (e.g., machine faults, shortages, quality defects)
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Allow frontline operators to pause the line when needed
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Escalate problems quickly to the right person
The system reflects the Lean philosophy of Jidoka, or “automation with a human touch,” where a process stops when an error occurs — so it can be fixed before causing larger defects or losses.
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Real-Time Problem Detection
Enables early action before issues escalate. -
Empowers Frontline Workers
Supports the Lean principle of respect for people by giving workers the authority to stop the process. -
Encourages Continuous Improvement (Kaizen)
Every alert is an opportunity to improve. -
Promotes Reflection (Hansei) After action is taken, teams often reflect on what went wrong and how to prevent it in the future.
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Builds Team Collaboration
Supports a culture where supervisors, quality, and maintenance all work together.
Conclusion: A Red Light That Drives Change
In traditional thinking, a red light means stop.
But in Lean thinking, it means: Start fixing. Start learning. Start improving.
🔴 Don’t hide the problem — highlight it.
Because what gets seen, gets solved.
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