Lean Manufacturing has transformed Mexican industry over the years, becoming the benchmark methodology for process improvement and continuous production enhancement. Visual management through Andon systems has become a vital element within the Lean production philosophy , providing visual and/or audible information about equipment, machines, workstations, and production lines. Andon is the link between people and data. Giving each stakeholder a clear picture of production, maintenance, quality, or materials goals and objectives will allow them to work smarter and more collaboratively.
What do we mean by visual production management?
Visual management is the ability of a system to quickly display the current status to anyone operating a machine or production line and observe, within 30 seconds, its operation. It can be the status of production, quality standards, the delivery status of materials, an anomaly, or the working condition of a machine. There are indicators so everyone knows how things are going. If visual management has been done well, EVERYONE within the factory will be able to understand and know how to solve a problem, especially if something is wrong.
Let's explain the key elements in a visual production management dashboard through Andon systems.
The key to growing a business is often the ability to empower people at all levels to make decisions and take ownership. Leadership in a Lean manufacturing process requires visual management and the work of managers and supervisors to achieve this empowerment. Visual management is the framework for communicating expectations, performance, standards, and issues in a way that requires little to no time to understand.
What is the purpose of having Andon systems for visual production management?
Visual management is used to share information, work standards, build on those standards, highlight problems, stop them from occurring and prevent them altogether.
Information sharing : One of the main objectives of using Andon systems for visual production management is information sharing. This information typically concerns daily operations, using metrics that display inputs, outputs, and any issues. This is one of the primary purposes of visual management using Andon: the ability to share information quickly, easily, and in real time.
Standardized work development : Andon helps establish operating and quality standards that all employees can see and adhere to. Visual management also has the ability to create standardized work and processes. Improving these standards is the primary goal of Lean philosophy, and above all, building a culture of continuous improvement. These standards should be based on new and improved processes that evolve the plant's production methods.
Another objective is to share standards on how work should be completed. This helps with shift changes and training staff on standardized work procedures. Having standard workflows will eliminate waste in the process, creating stability and consistency within a lean production system.
Highlighting problems : Another objective of visual production management using Andon technologies is to highlight problems when they occur, appear out of the ordinary, and deviate from the standard. Andon can highlight problems on the factory floor in real time, while metrics on visual dashboards highlight problems by hour, by day, by department, by production line, etc.
Problem-solving : Highlighting problems and issues in a visual management dashboard allows you to analyze and resolve the problem at the point of occurrence. This can accelerate the problem-solving process, generating quick results.
What are the benefits of visual production management with the implementation of Andon?
Time savings : Visual production management can reduce the time it takes to understand and process information and data. A visual dashboard can be considered efficient when it can communicate the status of the work area in 30 seconds and alert those with decision-making and response authority.
Real-time updates : Visual management creates a centralized location to store and host all data and its updates. It is typically updated daily to provide relevant information on production targets, maintenance objectives, quality, and issues related to procurement and materials.
Faster Problem Solving: Andon provides a structured system for analyzing and solving problems in a formal environment, helping technicians and supervisors accelerate the problem-solving process. For example, by using tools such as root cause analysis, even the most complex problems faced by businesses can be resolved in a timely manner.
Accountability : Visual production management fosters greater accountability for everyone involved in the process. It helps define roles, assign tasks, and establish a standard operating procedure. Everyone in the process takes ownership of their daily tasks.
Improved team performance : Enhanced accountability can lead to improved team performance. The purpose of visual management is to improve team performance and foster efficiency.
Waste reduction: Completing processes and workflows at the right time significantly reduces the amount of waste in the production process. Andon systems for smart factories provide technicians, line supervisors, and managers with the right information and data they need to improve process efficiency and eliminate waste.
An example to explain the benefits of an Andon system
Suppose that a control panel is installed to display production lines on screen and monitor ongoing operations. When an operator finds an anomaly, the system sends an alert via a digital work instruction they are viewing. The anomaly is then displayed directly on the screen to alert everyone.
This visual management system provides many measurable benefits for this example. Here are some:
Significant time savings : visualizing problems provides a better understanding of the situation by reducing and minimizing the waste involved in searching for information or the breakdowns that result in stopping the production line.
Cost reduction : Because time is money in the factory, reducing time can reduce production costs caused by unplanned downtime and that would ensure profitability.
Improved communication : The Mexican industry is characterized by the connectivity of its various stakeholders, who exchange information and data fluidly and in real time. Thus, the visual or auditory display of alerts promotes a better flow of internal communication among the different stakeholders, practitioners, facilitators, and supervisors.
Better control : By anticipating and forecasting problems, Andon allows maintenance teams and management to have more control over the production chain.
Information gathering : To develop and maintain visual production management systems, information about the operation of the production chain must flow from the lowest levels of the organizational hierarchy to decision-making positions. This will provide them with better visibility and understanding of how the production chain functions.
Andon is at the heart of the continuous improvement approach because it opens the door to various continuous improvement approaches that aim to optimize plant performance at all levels.
It is logical to say that Andon has a crucial place in Mexico's connected industry. Coupled with digital work instructions, operators now have all the tools to improve their productivity and efficiency.
MES AUTOMATION is the leader in implementing Andon solutions for digital transformation using visual production management systems with visual and audible alerts. We install Andon systems in factories across various industrial sectors, highlighting faults in the production line and ensuring better management of production downtime. Contact one of our technical advisors now to learn more about visual production management and how it can help your business grow by empowering your technicians and line supervisors.
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Originally published on May 31, 2022, updated on November 30, 2023
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