Andon: The Visual Management Tool

Imagine working on a factory floor. Machines are rumbling. Products are being assembled. Everything looks like it’s running fine… until something goes wrong. A part gets jammed. A tool isn’t working. Quality drops. But how would anyone know?

This is where Andon comes in.

Andon is more than just a tool — it’s a powerful communication system that helps teams spot problems quickly, fix them faster, and keep everything running smoothly. It’s one of the simplest yet smartest techniques used in Lean manufacturing.

In this blog, we’ll break down what Andon is, how it works, why it matters, and how companies big and small use it to create smoother, safer, and smarter workplaces.

What is Andon?

Andon is a Japanese word that means “paper lantern.” In the manufacturing world, it refers to a visual signal — like a light, sign, or display — that tells everyone when something has gone wrong.

Think of it as a factory’s version of a traffic light:

• Green means all is good.
  
• Yellow might mean something needs attention.
  
• Red means stop — there’s a problem.
  

But it’s not just about lights. It could be a screen showing production numbers, a sound alarm, or even a pull-cord an operator can use to call for help.

The main goal of Andon is to make problems visible.

Where Did Andon Come From?

Andon was popularized by Toyota as part of its famous Toyota Production System (TPS). Toyota believed that anyone on the production line — no matter their role — should have the power to stop the process if they see a problem.

Sounds risky? It’s not. It’s smart.

By giving every worker the ability to signal issues early, Toyota created a culture where quality and safety came before speed. Instead of hiding problems or waiting until they became big, people solved them in real time.

This is the heart of Andon.

Andon works as a real-time alert system that helps identify and respond to problems on the shop floor as soon as they happen.

Let’s break down how it functions in a typical manufacturing setting:

During production, if a worker notices an issue — such as a machine malfunction, a missing part, or a quality concern — they activate the Andon system. This can be done by pulling a cord, pressing a button, or using a touchscreen panel located at their workstation.

As soon as the Andon is triggered:

• A visual signal, like a red light, turns on above the workstation to indicate a problem.
  
• An audio alert, such as a chime or buzzer, is activated to grab attention.
  
• The production line may slow down or stop, depending on the severity of the issue and how the system is set up.
  
• A team leader or supervisor is notified and arrives at the station to assess the situation.
  

Once the issue is understood, the team either resolves it on the spot or takes the necessary steps to contain it. The focus is always on solving the problem correctly and safely — not just moving forward quickly.

After the resolution, the Andon signal is reset, the visual alert turns green, and normal operations resume.

This system ensures that problems are not ignored, and support reaches the exact spot where it’s needed — instantly and visually. Over time, this leads to fewer defects, safer operations, and a stronger culture of quality.

Types of Andon Signals

There’s no one-size-fits-all. Companies design their Andon systems based on their needs. But here are the most common types:

1. Light Towers
   
   • These are color-coded lights (green, yellow, red) placed above machines or stations.
     
   • They give a quick glance at status: Normal, Warning, or Problem.
     
2. Andon Boards
   
   • Large electronic displays that show the entire production line status.
     
   • They often show targets, actual performance, and problem alerts in real-time.
     
3. Pull Cords or Buttons
   
   • Placed near operators, these tools allow them to send a signal when something isn’t right.
     
4. Sound Alerts
   
   • Each issue may trigger a different tone or sound, helping teams know the type of issue even without looking.
     
5. Mobile Notifications
   
   • In modern factories, alerts can even go to smartphones or tablets, so team leaders can respond faster.
     

Why Is Andon So Effective?

Andon may seem like a small tool, but it delivers big results. Here’s why it works so well across different industries — from manufacturing floors to service desks.

1. Immediate Problem Visibility

In many workplaces, problems can stay hidden for too long. A machine might be slightly off, a part might not fit perfectly, or a step in the process might be skipped. These small issues can quickly turn into bigger ones.

With Andon, the moment something goes wrong, everyone knows. A light flashes, a chime sounds, or a message pops up. It removes the guesswork. This instant visibility helps the right people respond immediately — no delays, no confusion. It’s like having eyes and ears everywhere on the shop floor.

2. Empowered Employees

One of the most powerful things about Andon is that it puts control in the hands of the workers. Instead of waiting for a manager to spot an issue or hoping someone notices, employees are trusted to act the moment they see a problem.

This changes everything.

It builds a sense of responsibility. Workers no longer feel helpless — they feel valued and respected. They know their input matters. And when people feel empowered, they take more pride in their work, speak up more often, and contribute to a stronger team culture.

3. Reduced Waste

In Lean thinking, waste comes in many forms — extra movement, rework, overproduction, and even time spent fixing avoidable errors.

Andon helps cut waste at the source.

Instead of pushing through a problem and fixing it later (which often costs more), the team can pause, address it early, and avoid creating defective or unusable products. This means fewer wasted materials, less time lost, and fewer resources spent on redoing work. Over time, these small saves lead to major efficiency gains.

4. Better Quality

When issues are fixed as soon as they happen, the chances of a faulty product reaching the customer are much lower.

Andon promotes real-time quality control. It helps teams detect errors before they multiply — for example, stopping the line before an entire batch gets assembled with the wrong part.

This ensures that what reaches the customer is the best version possible. And when customers receive consistently good products, it builds trust and loyalty — two things that are hard to win and easy to lose.

5. Continuous Improvement

Every Andon alert is more than just a fix — it’s a clue. A signal. A chance to learn.

Over time, companies can track how often Andon is triggered, where it’s being used the most, and why certain issues keep coming up. This data is gold. It helps teams:

• Identify patterns
  
• Understand root causes
  
• Make permanent improvements
  

Andon, therefore, feeds into a cycle of learning and growth. It encourages reflection, drives smarter decision-making, and supports a culture where teams are always finding ways to get better.

How to Set Up Andon in Your Workplace

Here’s how to set up Andon in your workplace:

Step 1: Identify Your Process

Where do problems often occur in your workflow? Think about:

• Delays
  
• Quality issues
  
• Equipment failures
  
• Communication gaps
  

Step 2: Choose Your Signal Method

Pick what works best for your team:

• A simple light system?
  
• A pull-cord?
  
• A touchscreen panel?
  
• A mobile notification?
  

Start simple — fancy tech is nice, but clarity is more important.

Step 3: Train Your Team

This is critical.

Employees must know:

• When to use Andon
  
• What to do after it’s triggered
  
• How it helps everyone, not just managers
  

Make it safe to use. No blaming. No penalties.

Step 4: Assign Responders

Someone must take action when Andon is activated. That might be a team leader, supervisor, or technician.

Response must be:

• Fast
  
• Supportive
  
• Focused on fixing and learning
  

Step 5: Track, Review, Improve

Keep a log of Andon events. Use this data to:

• Spot recurring problems
  
• Analyze root causes
  
• Make changes that reduce future alerts
  

This is how Andon feeds continuous improvement.

Common Misconceptions About Andon

Even though Andon is a simple and powerful tool, many people misunderstand it. Let’s clear up some of the most common myths — and why they simply aren’t true.

 “Andon slows down production.”

At first glance, stopping a production line may seem like a bad idea. After all, isn’t the goal to keep things moving?

Yes, the Andon system might pause the workflow for a few minutes. But here’s the truth: those few minutes of pause can prevent hours of rework, defective products, or even equipment breakdowns down the line.

Andon is not about slowing down — it’s about solving problems before they grow. Would you rather stop for five minutes to fix a small leak, or keep running and flood the whole floor? That’s the difference. A short pause now can protect productivity in the long run.

 “Only big companies can use it.”

Many people believe Andon systems are expensive, high-tech tools only companies like Toyota or Amazon can afford. That’s not true at all.

Yes, big companies might use advanced Andon boards and automated alerts. But the heart of Andon is simply clear, immediate communication. And that can be done in very low-cost ways:

• A string and a bell.
  
• A whiteboard with marker signals.
  
• A sticky note system.
  
• A flashlight or manual flag.
  

You don’t need huge budgets or fancy equipment. What you do need is a mindset: one that welcomes early warnings and values frontline input. Any small business or team can start with a basic version and improve over time.

“It makes workers look bad.”

This is one of the most harmful myths — and also one of the most untrue.

Some managers worry that frequent Andon alerts mean their staff aren’t doing well. Others might think workers use the system to avoid work or point fingers. But that completely misses the purpose of Andon.

Andon is not about blame. It’s about support. When a worker triggers Andon, it shows they are:

• Paying attention to quality.
  
• Taking responsibility.
  
• Acting before a problem gets worse.
  

That’s exactly the kind of employee every company wants.

In fact, a good Andon culture recognizes and appreciates those who use it. Because every Andon pull is a sign that someone cares enough to speak up — and that’s something to celebrate, not criticize.

Final Thoughts: Why Every Workplace Needs an Andon Mindset

Whether you’re building cars, managing software, or serving customers — problems will happen.

The question is: will your team see them early and solve them together?

Andon helps you say “yes.”

It shines a light on the dark corners of your process. It makes quality everyone’s job. And it turns every small problem into a chance to learn, improve, and grow.

So if you want to create a workplace that’s clear, confident, and continuously improving — start with a simple Andon.

Sometimes, one light can change everything.