Calculate average andon response time from signal to resolution. Track escalation effectiveness and reduce production line stoppages.
An andon system is a visual signaling system that alerts team leaders and support personnel when a production line worker encounters a problem. The worker pulls a cord or pushes a button, triggering a light and/or sound that calls for help. The effectiveness of an andon system is measured by how quickly problems are responded to and resolved.
Fast andon response prevents small problems from becoming line stoppages. When response is quick (under 1 minute), many issues are resolved without stopping the line. When response is slow, operators either stop the line (reducing output) or let defects pass (creating quality problems).
This calculator computes key andon metrics: average response time, resolution time, calls per shift, and the percentage of calls resolved without stopping the line. Use it to benchmark your andon system effectiveness and identify improvement opportunities.
By calculating this metric accurately, production managers gain actionable insights that drive continuous improvement efforts and strengthen overall operational performance across the shop floor.
Andon response time directly impacts both quality and throughput. Every second of delayed response is a potential defect passed downstream or a line stoppage. Tracking these metrics drives faster response through accountability and proper staffing of support resources. Data-driven tracking enables proactive decision-making rather than reactive problem-solving, ultimately saving time, materials, and labor costs in production operations.
Avg Response Time = Total Response Time ÷ Number of Calls Avg Resolution Time = Total Resolution Time ÷ Number of Calls In-Station Fix Rate = Calls Fixed Without Stop ÷ Total Calls × 100% Calls per Shift = Total Calls ÷ Number of Shifts
Result: 30 sec avg response, 80% in-station fix rate
Avg response = 22.5 min ÷ 45 calls = 0.5 min (30 seconds). Avg resolution = 67.5 ÷ 45 = 1.5 min. In-station fix rate = 36/45 = 80%. Calls/shift = 9. Response is fast (under 1 min target). Resolution could improve to reduce the 20% that cause line stops.
Design a tiered escalation system: Tier 1 (team leader responds within 30 seconds), Tier 2 (supervisor joins at 2 minutes), Tier 3 (manager involved at 5 minutes). Automatic escalation ensures no call goes unresolved. Each tier has increasing authority to allocate resources.
Andon calls are a goldmine of improvement data. Pareto charts of call reasons by station reveal the biggest opportunity areas. Track hourly call patterns to identify timing-related causes. Monthly andon analysis should drive the improvement project selection process.
Andon embodies the Toyota principle of respect for people. It empowers every worker to stop production when quality is at risk. It provides immediate support when workers face problems. This mutual respect between management (providing resources) and operators (maintaining standards) is foundational to lean culture.
Andon is a lean manufacturing concept originating from Toyota. It is a visual and audible notification system where operators signal for help when they encounter a problem. The word "andon" comes from Japanese paper lanterns. Modern systems use colored lights, displays, and sound alerts.
World-class response time is under 30 seconds. Good performance is under 60 seconds. Over 2 minutes indicates inadequate team leader coverage or poor system design. At Toyota, the expectation is that a team leader responds within one takt time cycle.
The in-station fix rate is the percentage of andon calls resolved before the work piece moves past the fixed position stop. A high rate (80%+) means most problems are solved quickly without stopping the line. Low rates indicate either complex problems or slow response.
It varies by industry and process maturity. Assembly lines may see 20-50 calls per shift. A very low number may indicate operators aren't pulling andon (bad culture). A very high number indicates process instability. Track trends rather than absolute numbers.
No. The goal is to respond fast enough that the problem is resolved before a line stop is needed. Fixed position stops give the line a buffer — if the issue is resolved within the buffer time, the line continues. Only unresolved problems should cause a stop.
Leadership must actively encourage andon use. Respond immediately to every call. Thank operators for pulling andon. Never blame operators for problems they identify. Make response resources available (sufficient team leaders). Track and act on andon data daily.