Take control of production disturbances with quick communications

Quick reactions reduces production waiting times by up to 20%

Variations and deviations in production are part of the everyday working life at a production facility. Disturbances challenge business goals in terms of quality, quantity, and delivery times. 

When a disturbance occurs, quick communications can significantly reduce production waiting times. That is why a method is needed for exceptional situations which creates a clear process for the processing of production disturbances and assistance requests.

Typical characteristics of production disturbances: 

1

Long waiting times that affect all of production
2

The operating procedure for the problem-solving process is unclear, roles and responsibilities are not determined
3

The management of production requests is confusing and time-consuming, and no measurable data is collected on them

The goal is a shorter lead time

A shorter lead time can improve business productivity and competitiveness as well as customer satisfaction. A shorter lead time makes operations more agile and enables quicker reactions to the changes in operational environment.

The right aid at the right time

When the problem-solving process has been sufficiently determined, assistance requests can be targeted at the right persons right away. The procedure clarifies the operating model and introduces savings in terms of both time and money.

Reporting the root causes of problems

Production bottlenecks can be detected by observing the causes of disturbances. When production stoppages are systematically summed up in a database, it is possible to get at their ultimate causes in a systematic manner.

Improved supply security

By recognising disturbances, it is possible to reduce production surprises and achieve a better level of supply security.

See our solution

Metal industry

Food industry

Wood processing and construction industry

Assembling industry

Medicine, packaging, and other industries

Our solution: Andon is a ready-made and easy to use system for the management of production assistance requests

Andon by Pinja assists in the comprehensive development of productivity. It is a ready-made and easy to use system for the management of production assistance requests. In addition, the system introduces a clear process for the processing of production disturbances and assistance requests, helping in achieving a better level of supply security.

The goal of the system is to start the problem-solving process as soon as possible and to bring out the root causes for the problems encountered in production.

Andon's features

 

 

Andon – Benefits of the system:

  • More openness
  • More productivity
  • More flexibility
  • Fewer stoppages
  • Savings in terms of money and time

Andon – System functionalities:

  • Text message alerts
    An Andon alert can be sent via SMS to the right person.
  • Email alerts
    An Andon alert can be sent via e-mail to the right person.
  • Alert-TV
    An audio-visual alert on the info screen indicates the workstation that needs assistance.
  • Reporting
    Reporting indicates the average response time of the support organisation, the time it takes to repair faults, and the number of times a line, machine, or workstation has requested for assistance.

A clear operating process

The system introduces a clear process for the processing of production disturbances and assistance requests, helping in achieving a better level of supply security.

Data visualisation in support of management

The system makes the data relating to production assistance requests transparent and measurable. Data collection supports decision-making in the development of production smoothness. Visual data sharing in a factory environment increases interaction and improves data flows.

A visual and clear user interface

Assistance requests are done quickly and easily by the operator. The support organisation is likewise less burdened as assistance requests are targeted at the party that can react to the situation and start the problem-solving process.

Our customer experiences with the Andon system

Wärtsilä

“Virtually every assembly cell has an alert button that, when pressed, triggers a follow-up. The alarm is sent as a text message to three parties: manufacturing, logistics and quality assurance.” When a malfunction has been identified and a way to avoid it in the future, the matter is logged on the computer.

– Mikko Ketonen, Development Manager

BRP

Workplace workers have Andon remote controls. The remote control sends a signal to the Andon system, which activates the alarm information screens throughout production. Andon system reports are regularly used to identify areas for improvement. For example, reports can be searched for disruption times by team and reason code.