Andon System

Andon System – Real-Time Issue Tracking & Resolution

Our Andon System is designed to automate and optimize the entire issue tracking and resolution process in modern manufacturing environments.

🚀 The Challenge

Traditional production environments often rely on outdated communication methods. When an issue occurs, operators typically need to call, report manually, or escalate through unclear channels—leading to delays, confusion, and increased downtime.

⚙️ The Solution

The Andon System introduces a fully digital, real-time approach to issue management:

• Automatic issue detection directly from machines

• Manual reporting by operators in under 5 seconds

• Instant alerting of the right person or team

Alerts can be delivered عبر multiple channels, including voice calls, SMS, Microsoft Teams, email, and WhatsApp.

📡 Real-Time Visibility

The system tracks the full lifecycle of every issue:

• From detection to resolution

• With complete transparency across all levels

• Ensuring everyone knows what’s happening at any moment

🏭 Built for Any Factory

The solution is fully configurable and adaptable:

• Custom workflows based on plant structure

• Dynamic escalation matrices

• Alerts based on machine, line, or issue type

• Multi-stage escalation with different communication methods

📊 Data-Driven Performance

Beyond automation, the system unlocks valuable production insights:

• Real-time data collection from machines, lines, and operators

• KPI tracking, including:

  • MTBF (Mean Time Between Failures)

  • MTTA (Mean Time to Acknowledge)

  • MTTR (Mean Time to Repair)

  • MTTS (Mean Time to Solve)

🤖 AI-Powered Intelligence

Advanced AI capabilities turn data into actionable insights:

• Pattern recognition and predictive analytics

• AI-generated reports and trend forecasting

• AI chatbot with access to live factory data

👷 Workforce Efficiency Module

• RFID-based employee tracking (log in / log out)

• Productivity and performance monitoring

• Skill matrix for each operator

• Clear visibility into workforce utilization

🏗️ MES Integration

The Andon System is part of a broader MES (Manufacturing Execution System):

• Work order management

• Real-time Work-in-Progress (WIP) tracking

• Full production traceability

• Seamless planning and execution

📈 Business Impact

• Faster issue resolution

• Improved communication on the shop floor

• Reduced downtime

• Data-driven decision-making

• Continuous process optimization

➡️ Proven efficiency improvement: 14%–17% annually