Gemba Solutions ANDON scoreboard allows the real-time display of production data on the shop-floor, display and escalation of alerts when problems occur, and analysis of data on an historical basis. Introducing a level of flexibility that’s unavailable on any other Andon solution,  this is the missing piece in your company's lean manufacturing jigsaw.

Andon scoreboards have traditionally been a fairly basic and quite expensive addition to lean manufacturing programs.  The data they display is usually fixed, with restricted headings, and they limit you to a snapshot view of what’s currently happening on the shop-floor—once the display changes, the data is lost. Gemba Solutions has addressed these issues and provides a fully flexible and user-configurable LCD Andon display with a whole host of additional features.  

The new Andon Board with our user-friendly Andon Supervisor software , you can easily configure your displays to show whatever production data you think is relevant, ie. minutes of shift elapsed; minutes required to reach daily target; minutes behind target; TAKT time etc, and change the layout as often as you like.

Using TAKT times to plan your production

Enter your production requirements and the software will quickly calculate TAKT times and a production plan for your machines/lines that automatically takes account of planned down-time (ie. breaks etc). A visual on-target indicator will let you know how you stand against target in real-time and you can also view a profile of progress throughout the shift. The Andon Board will display values such as; minutes of shift elapsed; minutes required to reach daily target; minutes behind target; TAKT time.

It’s not just a snapshot...

Unlike a traditional Andon Board, the data collected by our solution will be saved, and provide you with an historical summary report showing shift and daily/weekly performance, including TAKT times, targets, actual production achieved, rejects, downtime, etc.

You can drill down into this data to find out where your problem areas and production bottlenecks lie, decide on changes to your process and then check your summary reports to ensure that your results have improved—no data is ever lost.

Get rid of all your spreadsheets and the headache that goes with trying to produce management reports each month, and use this mechanism to quickly and easily pull out what you need.

So, now you know how well or badly your production runs are going, but how do you know what to change if your results aren’t what you’d like them to be? With Gemba's Andon Board, you can utilise the powerful software to find out where your problem areas and production bottlenecks lie, decide on changes to your process and then check your summary reports to ensure that your results have improved – data is never lost. 

Go wireless…

Our flexible Andon solution offers a variety of ways to get data to your scoreboard. Our standard data collection terminals (Ethernet or wireless) can be installed at machine level and will pull data from your production process directly into our Supervisor software. Alternatively, we can provide you with WiFi button boxes that require no installation or cabling, can be positioned and moved wherever and whenever you like and provide a mechanism for an operator to call for help, flag a problem etc. Don’t let your system fall in to disuse just because you need to move a few machines around—move the button boxes too. They can be configured to record any type of event you require; Downtime, Setup Required, Material Shortages, Help required ...

And when there’s a problem...

Wouldn’t it be useful if your production process could automatically alert your staff to issues that need their attention, and then escalate alerts to senior staff when necessary? You can use our Andon solution to display alerts via your Andon scoreboard, as well as by other mechanisms including email, text message, pager, etc. With our Andon Supervisor software, you can create multi-step processes that allow your staff to react to situations as they occur.


Alerts can also be triggered automatically by an aspect of your production process:

A maintenance engineer is required
Material is required to restock your Kanban system
Your efficiency level has fallen below a given target
Your defect level has risen above a given threshold
A machine has broken down
A temperature/pressure/torque reading is out of tolerance 

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