Improve production with explitia.Andon
Andon system for real-time response to production issues
Modern manufacturing requires immediate reaction to deviations from standard. Delayed information about a problem leads to quality losses, downtime, and rising operational costs.
explitia Andon is a browser-based andon system that enables real-time reporting, visualization, and handling of production issues directly from operator workstations.
It combines the functionality of a classic andon light system with the workflow logic of an advanced andon call system, ensuring that operators, team leaders, and maintenance in your company work from the same live data source, eliminating the need for phone calls or paper notes, and reduces the delay in communication.
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Join our waitlist and be among the first to get explitia.Andon completely free of charge. Monitor reports, statuses, and team responses all in one place. No communication chaos, no delays, no reacting after the fact.
What You Get with the explitia Andon System?
If you are looking for an Andon system that improves daily production control, explitia Andon provides complete support for the problem-response process, starting with reporting and finishing with structured data analysis.
From your perspective as a production manager, you gain:
Immediate visibility of production issues
Standardized response procedures
Shorter reaction times and reduced downtime
Clear responsibility assignment
Full historical data for performance analysis
The system allows operators to report events such as machine breakdowns, quality issues, material shortages, or request support with a single click, either from an operator terminal or automatically via machine signals.
What Is an Andon System and How Does explitia Andon Work?
An andon system originates from Lean Manufacturing principles. Its purpose is simple: detect a problem quickly and respond immediately.
Traditionally, an andon light system uses visual signals (often colored lights) to indicate production status. explitia.Andon expands this concept into a digital andon call system, combining visual signaling with automated workflows, notifications, escalation paths, and analytics.
explitia.Andon can operate as:
- A standalone andon system (for example, as a pilot implementation),
- A component of a broader production ecosystem and MES environment.
The system collects signals from:
- Operator reports,
- Machines and controllers,
- Signaling buttons,
- Sensors and automation systems.
Every event is archived, visualized, and assigned to responsible personnel. The response process becomes measurable, structured, and repeatable.
Modules and functionalities of the Andon system:
Andon Calls – Immediate Reaction to Production Events
At the core of the system is instant issue reporting. An operator can:
- Report a problem with one click
- Select the type of issue
- Add comments and context
It enhances the traditional andon light system into a digital andon call system that connects production and maintenance in real time.
Instead of searching for a technician or reporting issues after the fact, every event is automatically routed to the right person.
Andon Board – Real-Time Production Status Visualization
The Andon board presents the current production status live. It includes:
- Color-coded event signaling
- Dashboards and event timelines
- Overview of all active calls
- Response status and assigned personnel
Unlike classic three-color andon light systems, explitia.Andon allows unlimited status categories and downtime classifications. You define the logic that matches your production environment.
The board can be displayed on large production screens, supervisor dashboards, or accessed directly from a browser.
Structured Handling and Escalation
Every andon call follows a defined handling process:
- Assignment of responsible person
- Automatic notifications
- Escalation rules
- Registration of reaction and resolution time
It can eliminate informal communication and provide full traceability. Maintenance effectiveness can be measured using actual response data instead of estimates.
Event History and Production Analytics
explitia.Andon includes advanced reporting functions:
- Number of calls by category
- MTTR (Mean Time to Repair) analysis
- Downtime root cause evaluation
- Pareto reports
- Maintenance and production KPIs
Collected data supports continuous production improvement and higher machine availability.
Integration with the production ecosystem
explitia.Andon can operate independently, but it is not an isolated application. It is part of a broader production environment.
Its integrations include, among others:
- the OEE module – providing availability data,
- CMMS – generating service tickets,
- the Production Portal and other analytical modules.
Andon collects machine operating statuses, and OEE uses this data to analyze efficiency, enabling the ecosystem to operate in a consistent and connected way.
Reduce downtime before it starts generating losses!
Contact us and see in practice how explitia.Andon streamlines the handling of production issues and supports fast response from operators, team leaders, and maintenance staff.
Why explitia Andon Stands Out Among Andon Systems?
| High Configurability | Unlimited downtime categories, fully customizable status logic, reporting scenarios adapted to your plant. |
| Scalable Deployment | Start with one line or workstation, implementation possible without PLC or ERP integration, pilot deployment within hours. |
| Modern Architecture | Web-based application, no user or call limits, full historical data archiving. |
Whether you need a simple andon light system replacement or a complete digital andon call system, explitia.Andon adapts to your operational structure.
How the Andon System Supports the Production and Sales Process?
Implementing an andon system can be the first step toward digitalization of production.
The process works as follows:
The operator reports a problem through the andon system
Maintenance or a team leader receives immediate notification
The system records reaction and resolution times
Data feeds OEE analysis and production reports
It helps you make every production issue measurable and traceable, from occurrence to root cause analysis.
Reliable delivery performance, stable production flow, and predictable downtime directly influence customer satisfaction and sales reliability.
Business Benefits of Implementing the explitia Andon System
Deploying explitia.Andon can result in tangible operational results:
- Shorter production downtime,
- Faster communication between departments,
- Increased machine availability,
- Measurable maintenance KPIs,
- Improved overall production efficiency.
Operators no longer need to look for technicians manually. Every issue automatically reaches the person responsible within seconds.
How explitia Andon Connects with Other Modules?
explitia Andon works independently but is also part of a broader Production Portal that may include:
OEE
Integration of Andon with the OEE module enables efficiency analysis in relation to reported problems and disruptions on the production line.
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EMS
Integration of Andon with EMS enables ongoing monitoring of events affecting energy consumption, supporting rapid response and better utility management in the production process.
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SPC
Integration of Andon with SPC enables ongoing detection of quality deviations and faster response to problems, while also supporting maintenance teams in reducing sources of disruption.
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CMMS
Integration of Andon with CMMS supports maintenance operations through automatic transfer of reports and faster response to machine failures and disruptions.
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Data flows between modules without the need for multiple disconnected systems. The Andon system becomes the foundation of real-time operational visibility.
The andon system gathers machine status information, while OEE calculations use these signals for performance analysis, which ensures data consistency across the production environment.
Implementation Process
The implementation of the explitia Andon system includes:
- Discovery Call
- Technical workshops and process analysis
- Preparation of a budget proposal
- Configuration of call categories and escalation paths
- Testing, system launch, operator and team leader training
Standard implementation time is approximately 2–4 weeks, with the option to expand into additional modules.
See How explitia.Andon Improves Your Production
If you are searching for a system that operates in real time and replaces a traditional andon light system with a structured andon call system, explitia Andon provides full production visibility and measurable response management.
You can implement this solution with us at no cost!
Fill in the contact form, and our team will get back to you to discuss the deployment of the explitia Andon system in your manufacturing plant and help you begin your digital transformation with structured, real-time production control.