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ABC Group Management Meeting: ANDON SYSTEM
ANDON
ABC Group Manufacturing
ABC Group Management Meeting: ANDON SYSTEM
ANDON: PLANT DISPLAY
Typical Display in Plant Location
Photo displays one of multiple data screens that will cycle through.
Note green for in control and red for out of pre-set parameters.
ABC Group Management Meeting: ANDON SYSTEM
ANDON
1.THREE PHASES– CALL FOR HELP– PRODUCTION MONITORING– PROCESS MONITORING
ABC Group Management Meeting: ANDON SYSTEM
PHASE 1: CALL FOR HELP
HMI unit installed on each assembly line– Individual IP address– Expandable to accommodate all three phases– Plant Responsibility
• Pre-wire plant with Network Cables and Power at selected location
• Install software in HMI unit and mount at assembly process• Locate and Install network PC with Indusoft Software• Locate and mount Audio and Visual Displays
– Group Support• Create Screens for HMI• Develop tracking system with MySQL database• Customise to Individual Plants • Provide files for installation on Server and HMI• Phone support and Remote connection to PC
ABC Group Management Meeting: ANDON SYSTEM
Call For HelpMain Screen
Typical HMI Call for Help Screen
Plan to introduce a second set of call buttons.
ABC Group Management Meeting: ANDON SYSTEM
Call for Technician
Operator will press the screen to initiate a Call for Help
A counter will immediately start tracking the response time.
An Audio and Visual indicator will be sent to the display panels throughout the plant
ABC Group Management Meeting: ANDON SYSTEM
Indicator Flashes Red After a Preset Time has Passed With No Response
Plant will set a response time target.
Data will be analysed to monitor performance to this target.
Target will be lowered once performance is met.
This allows the plant to monitor the effectiveness of the system and measure their ongoing improvements.
ABC Group Management Meeting: ANDON SYSTEM
Multiple Calls Can Be Made
ABC Group Management Meeting: ANDON SYSTEM
Technician has Closed IssueMaterial Handler Flashing Red
ABC Group Management Meeting: ANDON SYSTEM
On Line Viewing of Service Response Time
ABC Group Management Meeting: ANDON SYSTEM
By Date, Shift, Who, Time
ABC Group Management Meeting: ANDON SYSTEM
Select Date from Calendar
ABC Group Management Meeting: ANDON SYSTEM
Select Shift from Drop Down Menu
ABC Group Management Meeting: ANDON SYSTEM
Sort by who was called
ABC Group Management Meeting: ANDON SYSTEM
Select by Minimum Response Time
ABC Group Management Meeting: ANDON SYSTEM
To Save Processor Capacity Screen Does Not Update Until Refresh Button Selected
ABC Group Management Meeting: ANDON SYSTEM
Screen Refreshed
ABC Group Management Meeting: ANDON SYSTEM
CALL FOR HELP: Next Steps
1. Add Second Column to Call For Help Screen– Add ability to select machine down or up
• i.e. select Mat’l Handler (Machine Up) when low on components, upgrade to Mat’l Handler (Machine Down) when components out of stock and production stopped
– System may be able to prioritize call– Allows for clear recording of downtime
2. Potential to prioritize Call based on machine priority• i.e. Plant Manager (or designate) assigns a priority listing to all jobs
running.• System can redirect response based upon this priority list.
3. Downtime Tracking– Respondent to log in when they arrive
• Separate log for time to respond versus time to resolve issue– Respondent to log out and enter downtime code when issue resolved
4. Standards– All plants will develop a standard for response time– System will monitor time and indicate out of standard responses– Software will track and produce reports in order to allow plants to focus on
issues– Once standard is met, plant will be challenged to reduce time thus ensuring
ongoing continuous improvement.
ABC Group Management Meeting: ANDON SYSTEM
PHASE 2: Production Monitoring
1. Utilize Same HMI unit as Call For Help System
2. Plants must show evidence that they are utilizing CFH system effectively and pass the ABC Cat audit for TPS foundation implementation prior to moving to Phase 2
3. PRODUCTION MONITORING– Allows for on line reporting of all production– Operator/Line Leader (TBD???) will select part from menu
• Selection of part will call up a recipe for that part which will be used in OEE calculations
• Variations from recipe may be entered (labour, cycle)– Set-up will record changeover time– Reporting of
• Good Parts• Scrap (Including Reason Code)• Downtime (Reaction Time, Reason Code, Respondent Identity (TBD))
– Automatic OEE Calculation– Data export to CMS at Preset Interval (Hourly ?)
ABC Group Management Meeting: ANDON SYSTEM
Production Monitoring: Line Selection
Supervisory screen on HMI allows for viewing of any line on the production floor.
ABC Group Management Meeting: ANDON SYSTEM
Production Monitoring: Main Screen
Efficiency Calculation has already been changed to OEE
ABC Group Management Meeting: ANDON SYSTEM
Production Monitoring: Enter Good Part Manually
Calculation based upon part recipe stored in database.
ABC Group Management Meeting: ANDON SYSTEM
Production Monitoring: Multiple Part Reporting
ABC Group Management Meeting: ANDON SYSTEM
Production Monitoring: 5 Good Parts Added
ABC Group Management Meeting: ANDON SYSTEM
Production Monitoring: Enter Scrap and Reason
ABC Group Management Meeting: ANDON SYSTEM
Production Monitoring: Hit “Report Scrap” to update
ABC Group Management Meeting: ANDON SYSTEM
Production Monitoring: Scrap Reported
ABC Group Management Meeting: ANDON SYSTEM
Production Monitoring: Downtime and Reason
ABC Group Management Meeting: ANDON SYSTEM
Production Monitoring: Hit “Report Downtime”
ABC Group Management Meeting: ANDON SYSTEM
Production Monitoring: Downtime Reported
ABC Group Management Meeting: ANDON SYSTEM
Production Monitoring: Scrap Log
ABC Group Management Meeting: ANDON SYSTEM
Production Monitoring: Refreshed Scrap Log
ABC Group Management Meeting: ANDON SYSTEM
Production Monitoring: Next Steps
1. Change Efficiency to OEE: Completed
2. Develop Main Supervisory Screen– Ability to review any machine in facility or group (customisable)
– Create part selection screen by machine (WHO? Sup’r or OP)
• Database of recipes by machine and part number
– Enter changes to standard recipe (Supervisor only)
3. OEE calculation– Based upon recipe
– Need secondary visual indication at line to allow operators to see performance to standard
4. Report Production to CMS– Develop output file and system to ensure regular reporting.
5. Personnel Lists– Creation of for tracking downtime
– Maintaining and updating list
ABC Group Management Meeting: ANDON SYSTEM
Phase 3: Process Monitoring
1. Plants will need to demonstrate active use of Production Monitoring prior to implementing Process Monitoring
2. Recipe for part will call up a preset list of parameters– Parameters will have ranges for in control
– HMI will monitor various machine parameters
• Out of control parameters will have an escalation system.
– Parameter examples
• Cycle time
• Part weight
• Machine Controls
• Temperatures
• Motors
• Silo’s
• Blender’s
• Etc.
ABC Group Management Meeting: ANDON SYSTEM
Process Control: Blenders
ABC Group Management Meeting: ANDON SYSTEM
Process Control: Dryers
ABC Group Management Meeting: ANDON SYSTEM
ANDON: Next Steps
1. Select Compatible HMI unit 2 weeks
2. Complete Call for Help Screens 4 weeks
3. Create MySQL database for retention of data 2 weeks
4. Develop Production Reporting 6 weeks
5. Create Downtime/Scrap Codes and databases 3 weeks
6. Set-up reporting to CMS 2 weeks
7. Develop Process Monitoring 12 weeks
8. Plant Level Development– Customise Call for Help 3 days
– MySQL database 1 week
– Install hardware 3 weeks
– Install software and set-up IP addresses 2 weeks
– Set-up Indusoft Server 1 week
