22 February 2016 Page 1 Andon (Process Control Board)

Vaillant Training, Belper Author: Dave Bate 22 February 2016 Page 2 What is Andon ? A visual control that enables the operator to inform the Team Leader (or responsible line cover) that an abnormal condition exists. Note: IT IS NOT A TOOL TO STOP THE LINE, IT IS IN FACT A TOOL TO KEEP THE LINE RUNNING Japanese translation: Lantern Andon

Vaillant Training, Belper Author: Dave Bate 22 February 2016 Page 3 Process Control Overview SYSTEM HEALTHY 12: LINE 1 HELP EQUIP QUALITY PRE PLAN 153PROD 146 DOWN 021 PST Vehicle Flow L10 10% 30%50%70%90% ONE TOUCH FIRST TIME EVERY TIME ONE TOUCH FIRST TIME EVERY TIME ONE TOUCH FIRST TIME EVERY TIME ONE TOUCH FIRST TIME EVERY TIME Andon

Vaillant Training, Belper Author: Dave Bate 22 February 2016 Page 4 Is activated by : Provides real time information. Trigger for problem solving. Key driver towards Lean Manufacturing. Prevents concerns being passed onto the next process ie Supports JIDOKA Andon the process operator manually automatically by links to equipment

Vaillant Training, Belper Author: Dave Bate 22 February 2016 Page 5 PULL IF QUALITY OR SAFETY ISSUE PULL TO ALERT T/L OF ANY ABNORMALITY STOP- CALL- WAIT

Vaillant Training, Belper Author: Dave Bate 22 February 2016 Page 6 PROBLEM INDICATION RESPONSE

Vaillant Training, Belper Author: Dave Bate 22 February 2016 Page 7 What does it look like ? Simple to read. Information easy to understand at a glance. Prominent location for the line support to see. Shows location of the concern, not detail. SYSTEM HEALTHY 12: LINE 1 HELP EQUIP QUALITY PRE PLAN 153PROD 146 DOWN 021 PST Andon

Vaillant Training, Belper Author: Dave Bate Hardware overview: Pull cords and beacons SYSTEM HEALTHY 12: LINE 1 HELP EQUIP QUALITY PRE PLAN 153PROD 146 DOWN 021 PST Andon

Vaillant Training, Belper Author: Dave Bate SYSTEM HEALTHY 12: LINE 1 HELP EQUIP QUALITY ATTEND PRE CRD PLAN 153 PROD 146 DOWN 021 PST P How does it work ? Line running Andon

Vaillant Training, Belper Author: Dave Bate How does it work ? Concern - Cord Pulled Pull cords and beacons SYSTEM HEALTHY 12: LINE 1 HELP EQUIP QUALITY PRE PLAN 153PROD 146 DOWN 021 PST Andon

Vaillant Training, Belper Author: Dave Bate SYSTEM HEALTHY 12: HELP EQUIP QUALITY LINE 1 ATTEND PRE CRD PLAN 153 PROD 146 DOWN 021 PST P How does it work ? Relevant position lights up Andon

Vaillant Training, Belper Author: Dave Bate The marquee shows the following information: System healthy Production Held Information System fault Information Emergency Stop information Buffer warning levels Maintenance Call Information Marquee SYSTEM HEALTHY 12: LINE 1 HELP EQUIP QUALITY PRE PLAN 153PROD 146 DOWN 021 PST Andon

Vaillant Training, Belper Author: Dave Bate The purpose of the chimes is to alert the personnel in that area that there has been a change in status on either the line side equipment or on the local Andon board. Every team on the line is allocated a sounder. Each sounder has the ability to sound individual chimes. Every line is usually allocated two chimes: 1st chime is for the purpose of warning the local team. 2nd chime is for the purpose warning the whole line. Chimes Andon

Vaillant Training, Belper Author: Dave Bate 22 February 2016 Page 14 De-coupling and Managed Buffers. Effective use of an Andon system relies upon the introduction of de-coupled production lines with managed buffers. De-coupled lines allow production areas to stop without immediate effect to following and preceding areas. It ensures that, within reason, a continuous flow of production is maintained by using the managed buffers between the lines. Andon

Vaillant Training, Belper Author: Dave Bate 22 February 2016 Page 15 De-coupling and Managed Buffers. Stn 1Stn 60 Total line stop Stn1 - Stn 60 Line stop Stn 60Stn 41 Stn 40Stn 21 Stn 20Stn 1 Managed buffers Line stop Stn1-Stn20 Line stop Production continues until preceding buffer short Andon

Vaillant Training, Belper Author: Dave Bate 22 February 2016 Page 16 Time in secs No of pulls How big should the buffer be? Set the buffer quantity based upon the line performance / downtime Reduce buffers as pulls & downtime reduce How to manage the buffer? 10 mins ~ 5 cars (depends on Takt)