Andon Cord/Big Red Button
An andon cord, also known as a big red button, is a device that is used to signal for help or to stop a production line in the event of an emergency. Andon cords are typically located in easily accessible places on the production line, and they are connected to a central alarm system. When an andon cord is pulled, it activates the alarm and sends a signal to the appropriate personnel, who can then respond to the emergency.
Andon cords are commonly used in manufacturing environments, but they can also be found in other settings, such as hospitals, warehouses, and construction sites.
History of Andon Cords
The use of andon cords can be traced back to the early days of the Toyota Production System (TPS). In the TPS, andon cords are used to stop the production line whenever a problem is detected. This allows workers to quickly identify and fix the problem, preventing it from causing further defects or downtime.
Benefits of Using Andon Cords
There are several benefits to using andon cords, including:
- Improved quality: Andon cords help to improve quality by allowing workers to quickly identify and fix problems. This prevents defects from being passed on to the next stage of production.
- Reduced downtime: Andon cords can help to reduce downtime by allowing workers to quickly stop the production line when a problem is detected. This prevents the problem from causing further damage or downtime.
- Increased safety: Andon cords can help to improve safety by providing workers with a way to quickly signal for help in the event of an emergency.
Examples of Andon Cords
There are many different types of andon cords available, each with its own unique features. Some common types of andon cords include:
- Pull cord: A pull cord is a simple cord that is attached to a switch. When the cord is pulled, it activates the switch and sends a signal to the alarm system.
- Push button: A push button is a button that is pressed to activate the alarm system. Push buttons are often used in conjunction with pull cords.
- Wireless andon cord: A wireless andon cord is a cord that uses wireless technology to send a signal to the alarm system. Wireless andon cords are often used in areas where it is difficult to run wires, such as large warehouses or construction sites.
Conclusion
Andon cords are a valuable tool for improving quality, reducing downtime, and increasing safety in manufacturing and other industrial environments. By providing workers with a way to quickly signal for help or to stop the production line in the event of an emergency, andon cords can help to improve overall productivity and efficiency.
1. Andon Cord Systems
- Andon Cord System from Gems Sensors: https://www.gemssensors.com/products/andon-cord-pull-systems/
- Andon Cord System from SICK: https://www.sick.com/us/en/detection-and-ranging-solutions/safety-light-curtains-and-safety-switches/safety-switches/safety-pull-cord-switches/c/g271211
- Andon Cord System from Banner Engineering: https://www.bannerengineering.com/us/en/products/safety-switches/cord-pull-switches.html
These systems typically include a pull cord, a switch, and an alarm. When the cord is pulled, it activates the switch and sends a signal to the alarm, which can be a light, a siren, or both.
2. Wireless Andon Cord Systems
- Andon Cord System from JACO Electronics: https://www.jacoelectronics.com/products/safety-switches/andon-cord-pull-switches/
- Andon Cord System from Brady Corporation: https://www.bradysafety.com/safety-products/safety-switches/andon-cord-pull-switch
- Andon Cord System from Eaton: https://www.eaton.com/us/en-us/catalog/safety-switches-relays-controls/safety-switches/safety-pull-cord-switches.html
These systems use wireless technology to send a signal to the alarm, which gives them more flexibility in terms of placement.
3. Andon Cord Software
- Andon Cord Software from Andon Systems: https://www.andonsystems.com/andon-software/
- Andon Cord Software from iFactory Solutions: https://www.ifactorysolutions.com/andon-software/
- Andon Cord Software from InfinityQS: https://www.infinityqs.com/products/andon-system-software/
This software can be used to manage and track andon cord events, and to generate reports.
4. Andon Cord Accessories
- Andon Cord Enclosures: These enclosures protect the andon cord and switch from damage.
- Andon Cord Signs: These signs help to identify the location of the andon cord and to explain its purpose.
- Andon Cord Training: This training can help workers to learn how to use andon cords properly.
By using the right tools and products, you can ensure that your andon cord system is effective and efficient.
Related Terms to Andon Cord/Big Red Button:
- Gemba: A Japanese term that refers to the actual place where work is done. Andon cords are often used in gemba to allow workers to quickly signal for help or to stop the production line in the event of a problem.
- Jidoka: A Japanese term that means “automation with a human touch.” Jidoka is a key concept in the Toyota Production System, and it is based on the idea that machines should be designed to stop automatically when a problem is detected. Andon cords are one way to implement jidoka.
- Poka-yoke: A Japanese term that means “mistake-proofing.” Poka-yoke devices are designed to prevent errors from occurring in the first place. Andon cords can be used as a poka-yoke device by allowing workers to quickly stop the production line if they detect a problem.
- Quality at the Source: A manufacturing philosophy that emphasizes the importance of preventing defects from occurring in the first place. Andon cords can help to achieve quality at the source by allowing workers to quickly identify and fix problems.
- Continuous Improvement: A manufacturing philosophy that emphasizes the importance of constantly improving processes and products. Andon cords can help to facilitate continuous improvement by providing workers with a way to quickly identify and fix problems.
Other Related Terms:
- 5S: A workplace organization method that emphasizes the importance of sorting, setting in order, shining, standardizing, and sustaining. Andon cords can be used as part of a 5S program to help keep the workplace organized and efficient.
- Kaizen: A Japanese term that means “continuous improvement.” Kaizen is a key concept in the Toyota Production System, and it is based on the idea that processes and products can be improved on a daily basis. Andon cords can help to facilitate kaizen by providing workers with a way to quickly identify and fix problems.
- Lean Manufacturing: A manufacturing philosophy that emphasizes the importance of eliminating waste and improving efficiency. Andon cords can help to achieve lean manufacturing by allowing workers to quickly identify and fix problems, and by preventing defects from occurring in the first place.
These are just a few of the related terms that are often used in conjunction with andon cord/big red button.
Prerequisites
Before you can implement an andon cord/big red button system, you need to have the following in place:
- A clear definition of the problems that the andon cord system is intended to address. This could include things like quality defects, safety hazards, or production inefficiencies.
- A system for responding to andon cord pulls. This could involve having a dedicated team of responders, or it could involve training all employees on how to respond to an andon cord pull.
- A way to track and analyze andon cord pulls. This could involve using a simple logbook or a more sophisticated software system.
- A culture of continuous improvement. Andon cords are most effective when they are used as part of a larger effort to improve processes and products. This means that employees need to be encouraged to use the andon cord system and to suggest ways to improve it.
In addition to these essential elements, there are a few other things that can help to make an andon cord system more effective:
- Visual cues: Andon cords should be placed in prominent locations and should be clearly marked. This will help to ensure that employees know where to find them and how to use them.
- Training: Employees should be trained on how to use the andon cord system and on how to respond to an andon cord pull. This training should be repeated regularly to ensure that employees are up-to-date on the latest procedures.
- Empowerment: Employees should be empowered to use the andon cord system whenever they see a problem. This means that they should not be afraid of being punished or reprimanded for using the system.
By following these steps, you can help to ensure that your andon cord system is effective and efficient.
What’s next?
After you have implemented an andon cord/big red button system, the next steps are to:
- Monitor and track andon cord pulls. This will help you to identify trends and patterns, and to see which problems are most common.
- Analyze the data from the andon cord pulls. This will help you to understand the root causes of the problems that are being reported.
- Take action to address the root causes of the problems. This could involve making changes to processes, procedures, or equipment.
- Educate and train employees on the new processes and procedures. This will help to ensure that everyone is aware of the changes and that they know how to follow them.
- Monitor the effectiveness of the changes. This will help you to see if the changes are having the desired impact on the number of andon cord pulls.
Once you have taken these steps, you can begin to use the andon cord system as a tool for continuous improvement. By regularly monitoring and analyzing the data from the andon cord pulls, you can identify opportunities to further improve your processes and products.
Here are some additional tips for getting the most out of your andon cord system:
- Involve employees in the process. Ask them for their suggestions on how to improve the system and how to use it more effectively.
- Make sure that the andon cord system is easy to use. Employees should be able to pull the cord and report the problem without having to go through a lot of hassle.
- Respond to andon cord pulls quickly. The faster you respond to a problem, the sooner you can fix it and prevent it from causing further damage or downtime.
- Celebrate successes. When you make improvements to your processes or products as a result of using the andon cord system, take some time to celebrate the successes with your employees. This will help to motivate them to continue using the system and to suggest further improvements.
By following these tips, you can help to ensure that your andon cord system is an effective tool for improving your processes and products.