The Andon Cord is a concept originating from the Toyota Production System (TPS), which is a cornerstone of lean manufacturing. It refers to a system that empowers workers to stop the production line when they detect a defect, issue, or abnormality in the process. The term "Andon" comes from a Japanese word meaning "lantern" or "light," and in this context, it refers to a visual signaling system (often using lights) to alert supervisors and workers about problems.
Key Features of the Andon Cord System:
- Empowerment of Workers: Employees are encouraged to take ownership of quality and stop the production line if they notice any issues.
- Visual Management: The system uses lights or signals (e.g., red, yellow, green) to indicate the status of production and highlight problems.
- Immediate Problem-Solving: When the Andon Cord is pulled, supervisors and team leaders quickly address the issue to prevent defects from moving further down the line.
- Continuous Improvement: The system promotes a culture of identifying and resolving problems proactively, contributing to overall process improvement.
Andon Cord Issue:
An Andon Cord Issue refers to a situation where a problem is identified in the production process, and the Andon Cord is activated to address it. This could involve:
- A defect in a product.
- A malfunctioning machine or equipment.
- A safety concern.
- A deviation from standard operating procedures.
When the Andon Cord is pulled, production is halted (or slowed down) until the issue is resolved. This ensures that problems are addressed immediately, preventing further defects or inefficiencies.
Benefits of the Andon Cord System:
- Improved Quality: Defects are caught early, reducing waste and rework.
- Increased Efficiency: Problems are resolved quickly, minimizing downtime.
- Employee Engagement: Workers feel empowered and responsible for quality.
- Continuous Improvement: Issues are documented and analyzed to prevent recurrence.
