Andon Software Solution
for Grundfos
A manufacturing case study showcasing digital Andon alerts, real-time shop-floor visibility, production issue communication, and faster response to manufacturing issues.
Why Grundfos Needed Andon Software
Grundfos focused on improving manufacturing efficiency, reducing downtime, and creating faster communication when production issues occurred on the factory floor.
In a manufacturing environment, production issues need to be identified and communicated quickly so the responsible teams can take action. At Grundfos, the requirement was to strengthen real-time production monitoring, address issues promptly, and improve communication across the factory floor.
The Andon Software Solution was integrated with the existing manufacturing infrastructure to provide real-time alerts and visual indicators for production anomalies. This connected operators and responsible teams with immediate information about issues, helping them identify problems faster and take corrective action.
Faster Production Response Through Andon Software
The Andon solution creates a connected communication and escalation workflow that helps manufacturing teams identify issues, receive alerts, respond quickly, and track resolution in real time.
Challenges
Production Issues
Machine stoppages, quality issues, material shortages, and other shop-floor problems require immediate attention from the responsible teams.
Delayed Issue Communication
Production issues need to reach maintenance teams, supervisors, and other responsible personnel without depending on manual communication.
Limited Issue Status Visibility
Production teams need clear visibility into whether an issue has been raised, acknowledged, is under action, or has been resolved.
Unresolved Production Issues
Issues that remain unresolved require a structured escalation mechanism so the appropriate management level can be notified.
Shop-Floor Visibility
Operators and production teams need clear visual signals to understand the current condition of a station and whether assistance is required.
Results
Instant Issue Reporting
Operators can raise production, maintenance, or quality issues directly through tablets, smart workstations, or connected equipment.
Immediate Andon Alerts
Digital notifications and Andon tower lights immediately communicate production issues to the responsible personnel.
Clear Issue Status
Red indicates an issue has been raised, yellow shows that the issue is under action, and green indicates that the issue has been resolved.
Automatic Escalation
Issues that remain unresolved beyond configured thresholds can automatically escalate to the next level of management.
Centralized Andon Monitoring
A centralized dashboard provides real-time visibility into machines, stations, active issues, downtime, and production status.
From Production Issue to Resolution
The Andon workflow ensures that every production issue is reported, acknowledged, addressed, and escalated when required, creating a structured response process across the shop floor.
Raise Issue
The operator reports a production, maintenance, or quality issue using a tablet, smart workstation, electrical interface, or connected production equipment.
Acknowledge
The responsible maintenance team or assigned person receives the alert and acknowledges the issue, confirming that action has started.
Resolve
After corrective action is completed, the responsible person updates the issue and closes the event, confirming that the station has returned to normal operation.
Escalate
If an issue remains unresolved beyond the configured response or resolution threshold, the system automatically escalates it to the next level of management.
Red — Issue Raised
Assistance is required and the issue needs attention.
Yellow — Under Action
The responsible team has acknowledged the issue and is actively working on it.
Green — Resolved
The issue is resolved and the station has returned to normal operation.
One View for Every Production Issue
The centralized Andon platform gives production and plant teams real-time visibility into machines, stations, active issues, production lines, and downtime.
Monitor Issues From Machine to Plant
The Andon platform organizes manufacturing operations into a clear hierarchy, allowing teams to identify where an issue is occurring and monitor it at the appropriate operational level.
Production teams can move from overall plant visibility to the specific machine or station where attention is required.
Understand What Needs Attention
Instead of relying on separate communication channels, the centralized Andon environment brings active production information together for faster awareness and response.
Active Issues
View production issues that currently require attention.
Machine Status
Monitor the operational condition of connected machines and production stations.
Issue Response
Track whether reported issues are awaiting action, under response, or resolved.
Downtime
Monitor downtime information to understand production interruptions and recurring operational problems.
Centralized visibility helps production and plant managers understand where issues are occurring and where response is required.
Improve Issue Visibility, Response & Escalation
Explore how an Andon software solution can help teams report production issues in real time, notify responsible personnel, monitor issue status, and support faster resolution across manufacturing operations.
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