ANDON Industrial Automation

Comparison Between Old and Modern ANDON Systems:

In the world of Lean Manufacturing, ANDON systems play a crucial role in visual management by enabling quick communication of issues on the shop floor. Whether it’s a breakdown, material shortage, quality concern, or process deviation, ANDON acts as an early warning system that helps manufacturers react fast and maintain operational flow. 

Over the decades, ANDON technology has evolved significantly—from simple pull‑cord signals to advanced IoT‑powered digital dashboards. In this blog, we break down the key differences between old and modern ANDON systems, their advantages, and how organizations can benefit from upgrading. 

What Are ANDON Systems? 

ANDON originates from the Japanese word for “paper lantern,” symbolizing illumination. In manufacturing, it represents transparency, visibility, and continuous improvement. 

The basic purpose remains unchanged: 

  • Alert operators and supervisors of abnormalities 
  • Enable faster response 
  • Reduce downtime 
  • Improve quality and flow 

But the way ANDON works has evolved dramatically. 

Old-Type ANDON Systems (Traditional ANDON) 

Traditional ANDON systems were designed during the early Toyota Production System (TPS) era and are still used in many factories today. 

Key Characteristics 

a) Manual Activation 

Operators typically pulled a cord or pressed a button to trigger an alert. 

b) Basic Visual & Audio Alerts 

Flashing tower lights, sirens, or simple indicator panels. 

c) Limited Information 

The alert might only show: 

  • Machine stop 
  • Quality issue 
  • Assistance required 

Detailed data was rarely available. 

d) No Cloud or Network Integration 

Old ANDON systems worked locally with hardwired connections. No remote monitoring or analytics were possible. 

e) Reactive in Nature 

They notified supervisors only after an issue occurred. 

Advantages of Old ANDON 

  • Simple to use 
  • Low implementation cost 
  • Minimal training required 
  • Highly reliable (no software failures) 

Drawbacks of Old ANDON 

  • No real-time analytics or data logging 
  • Difficult to scale across multiple lines 
  • Cannot track trends or root causes 
  • Limited communication capability 
  • High maintenance due to wiring and hardware aging 

Modern ANDON Systems (Smart / Digital ANDON) 

With Industry 4.0, modern ANDON systems have transformed into powerful digital tools. 

Key Characteristics 

a) IoT & Sensor-Based Automation 

Alerts can be triggered automatically by: 

  • Machine sensors 
  • PLC data 
  • Quality inspection devices 
  • Productivity monitoring software 

b) Centralized Dashboards & Cloud Connectivity 

Managers can view line status from: 

  • Computers 
  • Tablets 
  • Mobile apps 

Whether on-site or remotely. 

c) Rich Information Display 

Digital ANDON boards show: 

  • Issue type 
  • Location 
  • Downtime duration 
  • Assigned team 
  • Escalation level 
  • Real-time performance metrics (OEE, cycle time, etc.) 

d) Predictive Capabilities 

With AI and analytics, modern ANDON systems can identify patterns and predict failures before they occur. 

e) Integration with Other Systems 

Modern ANDON integrates easily with: 

  • ERP 
  • MES 
  • Quality Management Systems (QMS) 
  • CMMS (Maintenance Systems) 

Advantages of Modern ANDON 

  • Real-time insights for fast decision-making 
  • Automated data collection and reporting 
  • Reduction in downtime through predictive alerts 
  • Enhanced collaboration using mobile notifications 
  • Improved traceability for audits and continuous improvement 

Drawbacks of Modern ANDON 

  • Higher upfront cost 
  • Requires IT knowledge for setup and maintenance 
  • Cybersecurity considerations 
  • Operator training needed 

Feature Comparison Table 

Feature Old ANDON Modern ANDON 
Alert Type Lights/Sirens Digital Boards, Apps, IoT Alerts 
Activation Manual Automatic + Manual 
Data Logging Very Limited Extensive, Real-Time 
Connectivity Local Wiring Cloud, Wi-Fi, IoT 
Integration Almost None ERP/MES/QMS Integration 
Analytics No analytics Predictive + BI Dashboards 
Scalability Hard to Scale Easily Scalable 
Maintenance High (hardware-based) Moderate (software updates) 

Why Manufacturers Are Upgrading to Modern ANDON 

Modern manufacturing demands: 

  • Faster response 
  • Higher quality 
  • Real-time insights 
  • Digital traceability 
  • Remote monitoring 

Modern ANDON systems support all these needs, making them essential for factories moving toward Industry 4.0 and smart manufacturing. 

When Should You Consider Upgrading? 

You may need to modernize your ANDON system if: 

  • Downtime is increasing 
  • Operators rely heavily on manual communication 
  • There is no real-time visibility across lines 
  • Reports are still prepared manually 
  • Management wants predictive analytics 
  • Your current system cannot scale 

Final Thoughts 

Both old and new ANDON systems serve the same foundational purpose—improving communication and response on the shop floor. But modern ANDON systems take this to a whole new level with IoT, automation, analytics, and integration capabilities. 

For organizations aiming to stay competitive, CIPL can help upgrade to a modern ANDON system that is more than a technological improvement—it’s a step toward smarter, leaner, and more efficient operations.