Vietsoft Successfully Implements ANDON System for DRÄXLMAIER Automotive
I. About the Client
DRÄXLMAIER Automotive Vietnam (DAV), a subsidiary of the German DRÄXLMAIER Group, specializes in providing electrical systems for high-end German car manufacturers. With over 70,000 employees across more than 60 locations in over 20 countries, DAV continually strives to enhance its production management quality. To improve production efficiency, particularly in reducing machine downtime caused by faults, DAV decided to implement a next-generation ANDON system.
II. Implementation of the Smart ANDON System at DRÄXLMAIER Automotive
The Smart ANDON system developed by Vietsoft is equipped with advanced data collection devices, mobile apps, and web apps, connecting and managing operations across the entire factory. The implementation of the ANDON system at DAV has significantly improved production management efficiency, minimized downtime, and increased productivity.
III. Introduction to ANDON Systems and Their Role in Production Management
The ANDON system, developed by Toyota and integrated into its production management system, is a crucial tool in Lean and Kaizen manufacturing practices, helping to manage quality and enhance work efficiency. The term “ANDON” in Japanese means “signal light” or “indicator light.”
The primary function of the ANDON system is to provide timely alerts about issues in the production process to ensure quick and effective intervention. This helps maintain product quality, minimize downtime, and improve the overall performance of the production line. The ANDON system supports the detection and resolution of problems as they arise, while also providing information for process improvement.
Basic Components of the ANDON System
1.Fault Notification Switches: Operators can use switches to report issues encountered during production. Typically, there are four different switches representing four main types of issues: a) Production faults; b) Equipment faults; c) Quality faults; d) Supply faults.
When an operator presses a notification switch, the information is transmitted to the responsible person for timely resolution.
2.Fault Communication Tools: Signal towers, sirens, or speakers are used to communicate information to the responsible person.
3.Production Status Display Screens: ANDON screens are used to provide a comprehensive overview of the status of each machine or production station for managers.
The ANDON system is widely used in companies that implement Lean Production models, particularly in the automotive parts manufacturing industry.
IV. Vietsoft’s ANDON 4.0 System
With the rapid advancement of the Internet and mobile technology, the ANDON system has been upgraded to Generation 4.0, featuring expanded and modern functionalities.
Comparison between Traditional ANDON and ANDON 4.0
Function
Traditional ANDON
ANDON 4.0
Fault Notification
Push button
Push button, mobile app, smartwatch, SMS
Fault Communication
Signal tower, speakers, sirens
Lights, speakers, sirens, mobile app, smartwatch, SMS
Data Storage for Analysis
Limited or none
Extensive and enhanced
ANDON 4.0 offers more advanced features compared to traditional ANDON systems, particularly with its data storage capabilities for improved analysis and efficiency. Remarkably, ANDON 4.0 is also more cost-effective than traditional systems, making it a strong contender in the market.
V. Application of the ANDON System at DRÄXLMAIER Automotive
The ANDON 4.0 system has been implemented in two workshops at DRÄXLMAIER Automotive Vietnam, with 62 users excluding machine operators.
After two months of implementation, the system is fully operational and has significantly improved production efficiency. The waiting time and issue resolution time have decreased by 23.5% within the first month of using the new system.
Figure 1.ANDON screen showing equipment status on the shop floor
With over two decades of experience in digital transformation for manufacturing enterprises, Vietsoft leads in providing consulting and implementation solutions for ANDON & OEE 4.0 production monitoring systems in Vietnam. With a team of experts rich in knowledge and practical experience, Vietsoft confidently partners with businesses to address challenges and embrace cutting-edge technologies.
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