Khái quát về ANDON SYSTEM là gì và lợi ích nó mang lại.
1. Thuật ngữ Andon System là gì ?
Trong lĩnh vực quản lý sản xuất hiện đại, Thuật ngữ hệ thống cảnh báo sản xuất Andon System là một thuật ngữ rất quen thuộc trong Hệ thống sản xuất Toyota (Toyota Production System)
Trong tiếng Anh, Andon được dịch là ‘Sign’ hoặc ‘Signal’. Có thể hiểu, Andon System là một hệ thống được thiết kế để quản lý quá trình vận hành và các sự kiện phát sinh trong quy trình sản xuất. Từ đó cảnh báo cho nhà quản lý hoặc nhân viên vận hành, kỹ thuật viên khi có bất kỳ vấn đề về chất lượng hoặc quy trình phát sinh.
2. Nguồn gốc xuất xứ của Andon System là gì ?
Sau khi đã hiểu rõ ANDON SYSTEM là gì, hãy cùng tìm hiểu về nguồn gốc của hệ thống này. Andon trong tiếng Nhật được hiểu là lồng đèn giấy, một vật rất phổ biến tại Nhật vào thời xưa. Sau này theo sự phát triển của xã hội Andon còn mang một nghĩa khác để chỉ hệ thống đèn (bảng) tính hiệu cảnh báo và thông tin tại các công trường, nhà máy để báo về tình trạng hoạt động sản xuất, thi công. Khi đèn này sáng màu xanh nghĩa là mọi hoạt động sản xuất đang diễn ra bình thường, đèn sẽ chuyển sang vàng để báo hiệu khi tiến độ công việc chậm và cần tập trung thêm người, khi có lỗi phải ngừng sản xuất đèn sẽ báo đỏ.
Sau này khi khái niệm sản xuất tinh gọn (Lean manufacturing) và phương pháp Jidoka của hệ thống sản xuất Toyota ra đời và trở nên phổ biến toàn cầu, hệ thống đèn Andon cũng được ứng dụng và cải tiến trở thành một hệ thống cảnh báo sản xuất Andon system như ngày nay.
Ban đầu trong dây chuyền sản xuất của Toyota, khi áp dụng phương pháp Jidoka các kỹ sư người Nhật đã đưa vào một hệ thống dây cảnh báo (Andon Cord), lấy cảm hứng từ các đèn hiệu Andon. Người vận hành sẽ kéo 1 sợi dây nằm phía trên đường dây Andon cord này để đưa ra các thông báo cho nhà quản lý về những vấn đề phát sinh khi phát hiện ra.
3. Hệ thống cảnh báo sản xuất ANDON hiện đại
Trước đây, hệ thống cảnh báo sản xuất Andon truyền thống thường chỉ bao gồm hệ thống tính hiệu để cảnh báo là chính, đa phần việc phát hiện, ghi chép và thống kê các lỗi phát sinh đều phải thực hiện thủ công bởi nhân viên vận hành. Điều đó dẫn tới việc tiêu tốn rất nhiều thời gian và công sức cho công tác này, nhưng đồng thời cũng dễ phát sinh ra các nhầm lẫn, thiếu sót do yếu tố con người mang lại.
Ngày nay, khi Jidoka được Toyota định nghĩa là “tự động hóa với tư duy con người”, hệ thống Andon system hiện đại cũng đã dần dịch chuyển theo hướng tự động hóa cao hơn. Một hệ thống Andon System hiện đại
như Smart Track được cấu thành từ nhiều yếu tố phần cứng phần mềm như: hệ thống cảm biến, Vi xử lý, phần mềm, server lưu trữ dữ liệu… cho phép hệ thống có khả năng tự động thu thập dữ liệu sản xuất, truyền tải và lưu trữ chúng đến server chuyên dụng theo thời gian thực. Đồng thời thông qua vi xử lý cùng phần mềm, hệ thống cũng có thể tự động phát ra cảnh báo cho người dùng khi vấn đề phát sinh.
Các dữ liệu sản xuất, thông tin sự cố cũng được lưu trữ trong cơ sở dữ liệu sản xuất chung của doanh nghiệp, cho phép người dùng có thể truy cập dễ dàng mọi lúc mọi nơi thông qua laptop hoặc smartphone.Nhờ những yếu tố đó, nhà quản lý cùng các kỹ thuật viên có thể dễ dàng kiểm soát toàn diện mọi vấn đề có thể phát sinh trong quá trình vận hành sản xuất ngay trên thiết bị cá nhân của mình.
Không những thế hệ thống Andon System hiện đại như Hệ thống quản lý sản xuất Smart Track còn có khả năng xử lý các dữ liệu thu thập tạo thành các báo cáo, đồ thị chi tiết giúp nhà quản lý có cái nhìn tổng quát về các vấn đề xảy ra trong ca làm việc.
4. Vậy lĩnh vực, ngành nghề nào có thể áp dụng hệ thống cảnh báo Andon system ?
Câu trả lời đó chính là hầu như mọi ngành nghề, lĩnh vực sản xuất ngày nay đều có thể áp dụng được hệ thống Andon. Tuy vậy với những doanh nghiệp sản xuất có quy mô nhỏ, việc quản lý và giám sát sản xuất chưa đòi hỏi nguồn lực quá lớn thì việc ứng dụng Andon system là chưa cần thiết.
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