An andon system lets an operator signal a problem at the station and brings the right person to help. Digital andon software routes each call by type, escalates it when nobody responds and logs it, so the stops that keep coming back are easy to see.
Showing 4 of 4 tools
Andon module within a shop-floor MES
Andon module from Canadian vendor 10in6 that routes operator help calls to maintenance, quality or team leads and times each call from trigger to resolution.
Cloud andon with downtime tracking
Cloud production system from Stermedia Group that combines andon alerts, line status tracking, downtime root-cause analysis and basic maintenance functions for factories.
Digital andon & connected worker
Mobile-first digital andon and escalation platform with SOP checklists, audits and an AI assistant for frontline teams.
Wireless call buttons and wearable alerts
Wireless call and paging system where a button at the station alerts the right person's smartwatch or pager and records the wait for each call.
The basics
Andon software lets anyone signal a problem and get help fast. A call goes to the right responder, appears on a board and is timed until it is resolved.
Andon comes from the Toyota Production System. It supports jidoka, the principle of stopping to fix problems at the source. The andon page explains the method.
Signals range from cords and buttons to stack lights, tablets and wearables. Many systems also let machines raise calls on their own.
A light and a clear rule for who responds can work on one line. People need to feel safe to call, and help needs to arrive.
Software helps when you want response times recorded, calls routed to the right team, and a history of which stops repeat.
The routine it supports
How the listed tools are priced
An operator presses a button, pulls a cord or taps a tablet and picks the type of problem, such as material, quality or maintenance. The software sends the call to the responder for that type and area and starts a timer.
The call shows on a stack light at the station and on an andon board or screen for the area. If no one responds in the agreed time, it escalates to the next level. When the problem is fixed, the responder closes the call with a reason.
Machines can raise calls too, for example on a fault or a low-material signal. Call data can feed downtime records in OEE software, so the two systems tell the same story.
Andon lights are stack lights or beacons at the station that show its status from a distance. An andon board is a larger display that shows the status of a whole line or area, with open calls and how long each has been waiting.
Wireless andon systems use battery or low-power buttons and lights, which avoids running cables to every station. They suit lines that move often, but check range and battery life in your building before you commit.
Software ties the hardware together and can also alert responders on phones or watches. Choose devices that work with gloves, noise and the distances in your plant, and that keep signaling locally if the network drops.
Decide who responds to each call type, how fast, and who comes next if the first responder is busy. Write those rules down before you configure them in the tool.
Andon supports jidoka: stopping to fix problems where they happen. It only works if people feel safe to call, so leaders should thank people for calls and respond quickly, especially early on.
Review call data regularly, for example at the daily tier meeting in daily management software. Pick the most frequent call reason and run a countermeasure on it.
Buying guide
Who it's for: Plant managers, production supervisors and lean leads in assembly, packing and machining areas. It suits sites that already practice stopping to fix problems and want faster response and better records.
One-touch calls from the station
A button, tablet or stack light the operator can trigger in one action, with a reason code picked from a list in seconds.
Escalation that matches your response rules
If the team leader does not respond within a set time, the call should move to the supervisor, then the manager, automatically.
Response and resolution timing
Separate clocks for time to respond and time to resolve. They point to different problems: staffing in one case, technical skill in the other.
Pareto of stop reasons
A simple ranking of calls by reason, station and shift. With this ranking, andon supports improvement work as well as raising alarms.
Before you choose
FAQ
Sources
Written by the lean-stack editors following our methodology. Updated October 3, 2026.
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