2025-09-09

Integration of Andon Systems with Industry 4.0 Technologies in Quebec

Integration of Andon Systems with Industry 4.0 Technologies in Quebec : In Brief

Andon systems, a legacy of the Toyota methodology, are experiencing a renaissance in the context of Industry 4.0 and Quebec's manufacturing digital transformation. Once limited to large manufacturing companies, these visual alert and machine connectivity systems are now becoming accessible to Quebec SMEs thanks to digital transformation. Technological evolution and industrial IoT now make it possible to implement these Andon dashboards at lower cost, while offering advanced real-time functionalities that integrate perfectly into the modern industrial ecosystem of Quebec's smart factories.

The Origin and Evolution of Andon Systems

From Cords to Tablets: Toyota's Legacy

Andon alert systems originate from Toyota's assembly lines. You've probably noticed those famous green-yellow-red lights in certain factories, but the concept goes far beyond that. Originally, it was simply a cord that operators could pull to signal a problem on the production line. This action triggered a visual signal (often illuminated) allowing a dedicated team to intervene quickly.

In traditional automotive assembly lines, with sometimes up to 400 workstations, an unresolved problem could quickly lead to a complete production stoppage. The Andon system revolutionized this dynamic by enabling immediate identification of the struggling workstation and targeted intervention.

The Democratization of Andon Systems for Manufacturing SMEs

For a long time, these visual control systems remained the preserve of large manufacturing companies, particularly in the automotive sector. The reason was simple: their implementation required substantial infrastructure – mechanical installations, complex wiring, expensive display panels. The value-effort ratio simply wasn't favorable for SMEs.

Today, in 2025, the situation has radically changed. Technological advances make it possible to implement Andon systems with minimal physical equipment. A simple tablet in an industrial case can now replace the cord systems, buttons, and lights of the past.

Andon in the Industry 4.0 Era

Digital Andon in Quebec: Much More Than Colored Lights

You may wonder how a concept as simple as Andon can integrate into the sophisticated ecosystem of Industry 4.0? The answer lies in the digital transformation of the concept within factories.

Modern Andon systems go far beyond visual alerts. They constitute true communication and incident management platforms:

  • Precise identification of the type of problem (technical, quality, logistics, etc.)
  • Automated notifications to concerned persons via SMS, Teams, emails
  • Customized sound announcements (some factories even associate specific melodies with each workstation, allowing identification of a problem's origin without even looking at a screen)
  • Intuitive user interface on tablet that allows the operator to specify the nature of the problem

Andon and MES Integration: The Power of Data

The truly revolutionary aspect of modern Andon systems lies in their ability to generate and analyze data through integration with MES (Manufacturing Execution Systems). Unlike traditional systems that were limited to signaling a problem, current digital solutions transform each alert into actionable data:

  • Number of calls per workstation and per period
  • Average response times
  • Responder performance
  • Resolution time by problem type
  • Identification of recurring problems

These statistics become powerful tools for continuous improvement teams, allowing identification of bottlenecks and process optimization. What was once a simple alert system transforms into a real internal ticket system, similar to those used in IT departments.

Implementation in Quebec SMEs

Unprecedented Accessibility

Andon dashboards and real-time alert systems are particularly relevant for Quebec manufacturing SMEs today due to their accessibility. Implementation no longer requires:

  • Massive infrastructure investments
  • Significant modifications to production lines
  • Specialized maintenance personnel

A simple standard commercial tablet, protected by an industrial case, is sufficient as an interface. The real value lies in the accompanying software, often offered as a SaaS (Software as a Service) model, significantly reducing initial costs.

Andon Systems for Manufacturing SMEs: Adapted Configurations

The flexibility of modern systems allows starting with a simple configuration and progressively evolving:

  1. Initial phase: basic alerts with email or SMS notification
  2. Intermediate phase: problem categorization and intelligent alert routing
  3. Advanced phase: integration with MES, ERP systems

This modular approach allows companies to adopt a system adapted to their current needs and evolve it according to their digital maturity.

Concrete Applications Beyond Production

Andon for All Departments

Contrary to popular belief, Andon systems are not reserved for production lines. In an Industry 4.0 perspective, they can be deployed in all departments of a manufacturing company:

  • In shipping: to signal labeling, packaging, or logistics problems
  • In warehouses: for stock shortages or access difficulties
  • In maintenance: to prioritize interventions
  • In quality control: to report recurring non-conformities

Advantages of Andon Systems for Quebec Industry

The implementation of Andon systems in the Quebec manufacturing ecosystem offers significant strategic advantages for local companies:

  • Improved competitiveness against international markets
  • Adaptation to specific constraints of the Quebec market (distance, weather, workforce)
  • Strengthening of local production capabilities
  • Facilitated integration with provincial digital initiatives
  • Reduced dependence on external expertise

Accessible "Quick Wins"

These real-time alert system implementation projects are generally considered "quick wins" - rapid victories with visible short-term ROI for the Quebec manufacturing industry. Immediate benefits include:

  • Reduced reaction time to problems
  • Decreased downtime
  • Better use of skills (the right people intervene on the right problems)
  • Creation of an incident database that becomes a valuable resource for continuous improvement

Conclusion

The integration of Andon systems with Industry 4.0 technologies represents a significant opportunity for Quebec manufacturing companies, particularly for SMEs. What was once a luxury reserved for large companies has become an accessible, flexible, and scalable solution.

Digital Andon systems perfectly embody the philosophy of Industry 4.0: they transform traditional processes by connecting them to the digital world via industrial IoT, generating valuable data while simplifying daily operations. Their implementation often represents an ideal first step in the digital transformation of a Quebec manufacturing company, combining modest investment and rapid return on investment.

At a time when responsiveness and agility are becoming key competitiveness factors, these Andon dashboards offer Quebec companies the necessary tools to identify and resolve problems before they significantly impact production, while building a culture of continuous improvement based on concrete data.

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