Andon, a signaling system born in Toyota factories in Japan, has evolved from simple cords and lights to sophisticated digital solutions. This Andon system radically transforms factory communication by enabling immediate response to problems. In 2025, Quebec companies, even manufacturing SMEs, can now implement these Andon systems at lower cost to significantly improve responsiveness to problems on the production floor, optimize response times, and generate valuable data for continuous improvement.
Andon is a concept from the Toyota production philosophy, initially developed for Japanese automotive assembly lines. In its original format, this system allowed each worker on an assembly line with sometimes up to 400 workstations to signal a problem by simply pulling a cord. This gesture activated visual signals (typically colored lights) that immediately alerted a specialized intervention team.
You've probably already noticed those famous green-yellow-red light indicators in some modern factories. This is the direct legacy of a system that revolutionized real-time problem management in the manufacturing industry.
For a long time, implementing an Andon system represented a substantial investment, primarily accessible to large companies. The necessary infrastructure (wiring, physical buttons, display systems) made the value-effort ratio unattractive for Quebec manufacturing SMEs.
The digital revolution has completely changed this equation. Today, in 2025, the Andon system has become accessible to all companies, regardless of their size. You might wonder how this transition occurred? The answer is simple: digital tablets have replaced complex physical mechanisms.
Installing a modern Andon system in a Quebec SME no longer requires heavy infrastructure. A tablet with the appropriate software is sufficient to create an effective signaling point. This modest cost allows the system to be deployed at multiple strategic locations throughout the factory.
Simplicity of use is at the heart of the concept:
Gone are the days of wasted time looking for a supervisor who could be anywhere in the factory. Gone are the prolonged interruptions and the "madhouse" where everyone is looking for everyone else to solve a simple problem.
The digital Andon system acts as a true catalyst for communication between different production floor actors. It eliminates traditional friction by establishing a direct channel between the operator experiencing a problem and the people with the expertise to solve it. This intelligent industrial signaling fundamentally transforms the problem-solving dynamics in the factory by making communication instantaneous, targeted, and traceable.
The modern Andon goes far beyond simple indicator lights. The system can now communicate via:
Some factories have even adopted unique sound signals for each station - a specific melody that allows responders to instantly identify the source of the problem without even looking at a screen. You hear the "Imperial March" from Star Wars? That's station 1 signaling a problem!
The true revolution of the modern Andon lies in its ability to generate actionable data. Unlike old purely mechanical systems, digital platforms automatically record:
These statistics transform the Andon into a true internal ticketing system, comparable to what is found in IT services. For continuous improvement teams, this data is a goldmine for identifying recurring problems and prioritizing optimization projects.
One of the great advantages of the modern Andon is its flexibility. A Quebec company can start with a basic system. It can then evolve according to its needs. It becomes possible to progressively add new functionalities. Automatic escalation levels represent an interesting first evolution. Sophisticated rule engines constitute a next step. Integration with other factory systems generally completes the deployment.
This adaptability makes it an excellent "quick win" project. Andon offers a rapid return on investment. It also lays the groundwork for future improvements.
A common mistake is thinking that Andon only concerns production stations directly linked to machines. In reality, any workstation in a factory can benefit from this production alert system.
Imagine a shipping operator encountering a problem with their label printer. Rather than abandoning their post to seek help, a simple click on the tablet can indicate "printer problem" and directly alert the IT department.
Andon represents one of the most accessible and profitable investments today for improving communication on the production floor of Quebec factories. Its digital transformation has democratized access to this practice once reserved for large industrial groups.
For Quebec manufacturing SMEs, adopting a modern Andon system offers a triple advantage: increased responsiveness to problems, significant reduction in downtime, and automated collection of valuable data for continuous improvement. The Andon system directly improves communication on the production floor by establishing clear, fast, and efficient exchange channels between all stakeholders.
In a context where competitiveness relies on operational efficiency, Andon is no longer a luxury but a necessity. Its simple, fast, and inexpensive implementation makes it a priority project for any manufacturing company concerned with optimizing its internal communication and productivity.
Sign up to follow manufacturing news.