Skip to content
☰
Request Demo
PPE background

Digital Andon System for Real-Time Manufacturing

Detect production issues instantly, alert the right people, reduce machine downtime and monitor your entire manufacturing operation from one intelligent Andon platform.

SCHEDULE A DEMO

Digital Andon Software

Turn Every Production Issue Into an Actionable Event

Digital Andon System connects operators, maintenance teams, supervisors and plant management through a real-time issue management and escalation platform.

Digital Andon dashboard showing real-time production issue status

Instant Issue Reporting

Operators can raise production, maintenance or quality issues directly from tablets, smart workstations or connected equipment.

Immediate Alerts

Andon tower lights and digital notifications immediately communicate the issue to responsible personnel.

Real-Time Visibility

Plant and production managers get a centralized view of machines, stations, active issues and downtime.

How It Works

How Does an Andon System Work?

A simple digital workflow ensures every production issue receives the right response within the expected time.

1

RAISE ISSUE - Operator Reports an Issue

An operator raises an issue using a tablet, electrical interface, smart workstation or connected production equipment.

RED • Action Required

2

ACKNOWLEDGE - Responsible Team Responds

Maintenance or the assigned responsible person receives the alert and acknowledges the issue.

Yellow • Under Action

3

RESOLVE - Issue Is Resolved

After corrective action is completed, the responsible person updates the issue and closes the event.

Green • Resolved

4

ESCALATE - Automatic Escalation

Issues that remain unresolved beyond configured thresholds are automatically escalated to the next level of management.

Escalation

Request Demo
Diagram showing the Andon issue escalation workflow from reporting to resolution

TOWER LAMPS

Andon Tower Lamp Integration

The Andon System integrates with physical tower lamps installed at manufacturing stations, providing clear visual status indication on the shop floor. This enables operators and production teams to immediately identify issues, track response status, and confirm when the station has returned to normal operation.

Red Red tower light indicating an issue has been raised

Red → Issue Raised

The operator has reported an issue and assistance is required.

Yellow Yellow tower light indicating the issue is acknowledged and under action

Yellow → Issue Acknowledged / Under Action

The responsible team or person has acknowledged the issue and is actively working to resolve it.

Green Green tower light indicating the issue is resolved and operation is normal

Green → Issue Resolved

The issue has been resolved and the station has returned to normal operation.

KEY FEATURES

Key Features Digital Andon Software

Replace manual production communication with a connected Andon platform designed for modern manufacturing.

Digital Andon Alerts

Instantly communicate machine and production issues using digital alerts and physical Andon tower lights.

Central Andon Dashboard

Monitor the real-time status of machines, stations and production lines from a centralized dashboard.

Mobile Monitoring

Authorized users can monitor production issues remotely using the mobile application.

Automatic Escalation

Automatically escalate unresolved issues based on configured response and resolution thresholds.

Issue Management

Record issue categories, responsible personnel, response times, corrective actions and closure details.

Downtime Analytics

Analyze downtime patterns, recurring issues and major production losses using real-time and historical data.

AI Solution Advisor

Use historical issue and resolution data to help maintenance teams identify relevant troubleshooting and corrective-action information.

IoT & PLC Connectivity

Connect machines, PLCs, sensors and industrial equipment to automatically generate manufacturing events.

Cloud-Based Platform

Access centralized manufacturing information from anywhere through web and mobile applications.

Manufacturing Analytics

Reports & Analytics

The Andon System converts production issue data into actionable insights, helping manufacturing teams monitor performance, identify recurring problems, reduce downtime, and drive continuous improvement.

Andon system reports dashboard overview

Reports

The system provides comprehensive reports for:

  • Manufacturing issue management

  • Downtime tracking

  • Maintenance response

  • Performance analysis

  • Historical insights

Andon system analytics dashboard overview

Analytics

Andon analytics provide key manufacturing performance indicators like:

  • Mean Time to Repair (MTTR)

  • Mean Time Between Failures (MTBF)

  • Pareto Analysis

ENTERPRISE INTEGRATION

ANDON Enterprise Integration

The Andon System integrates with enterprise and manufacturing applications, creating a connected manufacturing ecosystem. Production events, equipment conditions, downtime, and issue status flow seamlessly across systems.

Possible integrations include:

ERP & SAP

MES

PLC systems

Production systems

IoT platforms

Maintenance systems

Quality systems

Power BI & Tableau

ANDON

ERP & SAP

MES

PLC systems

Production systems

IoT platforms

Maintenance systems

Quality systems

Power BI & Tableau

Cloud-Based Andon System

The solution is ideal for organizations with multiple manufacturing plants and geographically distributed production facilities.

Key Capabilities:

  • Centralized Visibility

  • Multi-Plant Monitoring

  • Multi-Line Tracking

  • Web Access

  • Mobile Access

  • Real-Time Monitoring

Cloud-based Andon system monitoring multiple manufacturing plants

AI-Powered Andon Support:

The Andon Solution Advisor can use historical issue and resolution information to assist maintenance and production teams when similar problems occur.

Analyze previous machine issues

Identify recurring problems

Find previous corrective actions

Support maintenance troubleshooting

Build organizational knowledge from historical data

Andon Solution Advisor interface showing AI-assisted issue analysis

Mobile Andon Notification

Critical manufacturing events can be communicated through multiple notification channels.

Mobile Andon app used by a worker on the shop floor

  • Mobile App

    Receive Andon alerts and monitor production status from your mobile device.

  • WhatsApp

    Send configured manufacturing alerts through WhatsApp notification workflows.

  • SMS Alerts

    Notify responsible personnel about important production events and escalations through SMS.

Manage Your Entire Manufacturing Hierarchy:

Organizations can configure multiple plants, production lines, workstations, and machines according to their manufacturing structure. This makes it easy to monitor issues at different levels, from an individual machine to the entire plant.

Plant

Production Line

Station

Machine

Overview of the manufacturing hierarchy from plant to machine level

Why Leading Organizations Choose Our Digital Andon Software?

A cloud-based Andon platform provides centralized visibility across manufacturing operations. Organizations can monitor multiple plants and production lines from a single platform while authorized users can access information through web and mobile applications.

Operator using the Digital Andon software on a factory floor

Manufacturing Focus

Designed around real production, maintenance and manufacturing workflows.

Industry 4.0 Ready

Connect machines, people, production systems and enterprise applications.

Cloud & Mobile

Monitor production operations through centralized web dashboards and mobile applications.

Enterprise Integration

Integrate with ERP, SAP, MES, PLC and other manufacturing systems.

Analytics Driven

Turn production issue data into MTTR, MTBF, downtime and Pareto-based improvement insights.

Scalable Architecture

Configure plants, lines, stations and machines according to your manufacturing structure.

Industries we serve

Automotive

Electronics

Aerospace

Industrial Machinery

Electrical Manufacturing

Consumer Goods

Our Trusted Clients

We’re proud to collaborate with industry leaders and innovative companies

Client 1
Client 2
Client 3
Client 1
Client 2
Client 2
Client 2
Client 2
Client 3
Client 3
Client 3
Client 3
Client 3
Client 3
Client 3
Client 3
Client 3
READY TO STRENGTHEN WORKPLACE SAFETY?

Reduce Downtime With Digital Andon

Connect your operators, machines, maintenance teams and management with a real-time Andon System built for modern manufacturing.

Schedule a Demo Contact Sales

Digital Andon System Software - FAQ

An Andon System is a manufacturing visual management and issue escalation system that allows operators to report production or machine problems and alerts responsible personnel so that issues can be resolved quickly.
Typically, red indicates that an issue has been raised, yellow indicates that the issue is being attended to, and green indicates that the issue has been resolved.
Yes. Escalation rules can automatically notify supervisors or senior management when an issue is not acknowledged or resolved within the configured time.
Common KPIs include MTTR, MTBF, downtime, issue frequency, resolution time, response time, escalation performance and top downtime reasons.
Yes. Enterprise integration can connect the Andon platform with SAP, ERP, MES, PLCs and other production systems, depending on the organization’s architecture and integration requirements.
Yes. A centralized dashboard can provide real-time visibility across configured plants, production lines, stations and machines.
Yes. With a cloud-based Andon platform and mobile application, authorized users can monitor production issues remotely and receive notifications through configured channels such as mobile app, SMS and WhatsApp.