Andon Light
System for
Manufacturing

Real-time visual signals that cut downtime before it cuts your output.

Andon lights give your production floor a voice. The moment a problem appears, a machine fault, a quality issue, or a line delay, the light signals it instantly. No waiting. No guessing. Just faster response and less downtime.

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What is an Andon Light?

Walk into any well-run factory floor, and you'll spot them immediately: stacked, colour-coded lights mounted above machines, workstations, or assembly cells. These are Andon lights, and they do one job exceptionally well — they tell everyone on the floor exactly what is happening right now without a single word spoken.

Today, Andon lights are used across automotive plants, electronics assembly, food processing units, pharmaceuticals, and any facility where production consistency matters. They are the simplest, fastest, and most reliable way to surface a floor-level problem to the right person before it compounds.

A basic Andon light setup uses three colours:

Normal Operation

Production is running normally

Warning

A minor issue that needs attention

Production Stopped

Immediate action required

How Does an Andon Light System Work?

An Andon light system follows a simple principle, make every problem visible the moment it happens. Complexity is the enemy on a shop floor where every second of downtime costs money.

Problem Detected

An operator notices an issue such as a machine fault, component shortage, quality defect, or inability to maintain line speed. The Andon signal is triggered using a button, cord, or automated sensor.

Signal Activated

The Andon light changes colour and a buzzer may sound. Digital alerts are sent to supervisors, handheld devices, or central dashboards in connected environments.

Response Triggered

Supervisors or team leaders respond immediately, typically within 30–60 seconds, to resolve the issue before it impacts the entire production line.

Problem Resolved or Line Stops

Minor issues are fixed without stopping production. If unresolved, the line is intentionally stopped to prevent defects. Once resolved, the system is reset.

Data Captured

Every Andon event is logged with timestamps, issue type, and resolution time. This data supports maintenance planning, OEE tracking, and continuous improvement.

Continuous Improvement

Insights from Andon data help identify recurring issues, optimize processes, and improve operational efficiency across the production line.

The power of this system is not in the hardware, it is in the discipline it enforces. Problems cannot be hidden. Response times are measured. Every stoppage becomes a data point that drives the next improvement.

Types of Andon Light

Not every facility has the same layout, noise level, visibility requirement, or budget. Andon lights come in several configurations, each suited to a specific environment.

1. Steady with Buzzer

Constant illumination with audible alert.

Operation	Steady
Power Supply	AC/DC 24V (±10%)
Buzzer	85dB
Lens Color	Red, Yellow, Green
Max Tier	3

2. Flashing with Buzzer

Indicates urgency using flashing signals.

Operation	Flashing
Power Supply	AC/DC 24V (±10%)
Buzzer	85dB
Lens Color	Red, Yellow, Green
Max Tier	3

3. Wall Mounted (With Buzzer)

Compact wall-mounted signal with sound alert.

Operation	Steady
Power Supply	AC/DC 24V (±10%)
Buzzer	85dB
Lens Color	Red, Yellow, Green
Max Tier	3

4. Wall Mounted (No Buzzer)

Silent visual alert for low-noise areas.

Operation	Steady
Power Supply	AC/DC 24V (±10%)
Buzzer	No
Lens Color	Red, Yellow, Green
Max Tier	3

5. Beacon Light

High visibility for large areas.

Type	Incandescent / Xenon
Power	AC/DC 24V
Buzzer	80 dB
Rotation	130/min
Flashing	80/min

6. Wireless Andon

Flexible wireless setup.

Operation	Steady
Range	50 m
Power	AC/DC 24V
Buzzer	85dB

7. Ethernet Andon

Connected to network systems.

Operation	Steady / Flashing
Communication	Ethernet
Systems	Max 5
Power	AC/DC 24V
Buzzer	85dB

Andon Lights for Industry 4.0

Modern manufacturing demand data, not just signals. Our integrated systems bridge the gap between physical lights and digital analytics.

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Data Logging

Every signal state is recorded for historical uptime reports.

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OEE Tracking

Automatically calculate Equipment Effectiveness based on signals.

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MES Integration

Sync light status directly with your Management System.

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Real-time Dashboards

View floor status from any device, anywhere in the world.

Transformation at the Edge

Traditional Andon lights were isolated signals. Industry 4.0 Andon systems are the nervous system of your digital twin factory.

Reduce MTTR (Mean Time To Repair) by up to 35%
Automated escalations via SMS/Email for unaddressed faults
Seamless integration with Allen Bradley, Siemens, and Omron PLCs

Benefit Value

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Reduce Downtime

Slash response intervals with instant visual notification of every line issue.

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Faster Response

Empower maintenance and management teams to prioritize critical faults using clear color-coded indicators.

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Improve Productivity

Minimize idle time and optimize workflow through clear communication at the point of activity.

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Real-time Visibility

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Data-driven Decisions

Andon System FAQ

What is an Andon system in manufacturing?

An Andon system is a visual management tool used on factory floors to quickly communicate the status of machines, processes, or production lines using lights, alerts, or digital displays.

How does an Andon system work?

Operators or machines trigger alerts when issues occur. The system displays these alerts using color-coded lights or dashboards, allowing supervisors to respond immediately and resolve problems.

What do Andon light colors represent?

Typically, green indicates normal operation, yellow signals a warning or minor issue, and red represents a critical problem requiring immediate attention. Color meanings can vary by organization.

Why is an Andon system important in Industry 4.0?

Andon systems improve real-time visibility, reduce downtime, enhance productivity, and enable faster decision-making by integrating with smart manufacturing and IoT-based systems.

Can Andon systems integrate with existing machines?

Yes, modern Andon systems can integrate with PLCs, sensors, and existing equipment, as well as MES and ERP systems, making deployment flexible and scalable.

What are the benefits of using an Andon system?

Benefits include faster issue resolution, reduced downtime, improved communication, enhanced quality control, and better overall operational efficiency.

How does an Andon system improve productivity?

By instantly highlighting issues and enabling quick response, Andon systems minimize delays, prevent escalation of problems, and keep production lines running smoothly.

Andon LightSystem forManufacturing