Digital Andon Board: Real-Time Visibility on the Shop Floor

A machine grinds to a halt – and on a busy shop floor, no one notices for minutes. A digital Andon board closes exactly this gap: it makes the state of production visible in real time and automatically alerts the right people before a brief fault turns into a costly stoppage.

What is a digital Andon board?

A digital Andon board is a software-based display that shows production status, output quantities, cycle times, and faults in real time. The term “Andon” originates from the Toyota Production System and refers to a visual signaling system that immediately makes operators aware of problems in the process. While the classic version is a simple traffic light in red, yellow, and green, the digital version can be linked to any machine data and KPIs.

This turns the Andon board from a mere warning light into a central building block of digital shop floor management: it bundles information that would otherwise be scattered across individual machines and systems.

How does a digital Andon board work?

Connecting data sources

A digital Andon board is only as good as its data. Through interfaces such as PLC, OPC UA, MQTT, or direct database and ERP connections, machine states, quantities, and cycle times flow onto the board in real time. The article From sensor to actuator shows how a simple sensor signal becomes usable information.

Signaling and escalation

As soon as a defined threshold is breached – for example a machine stop or output falling below target – the board changes status and triggers an escalation. This can be a color change, a message on a large screen, or a notification to maintenance and shift management. Passive display becomes active shop floor communication.

Classic vs. digital Andon board

The classic Andon light signals only one state and must be triggered manually. A digital Andon board captures states automatically, combines several KPIs, stores the history for analysis, and can be adapted without changing hardware. That makes it a central tool of visual operator management.

Benefits for production and maintenance

• Faster response times: faults become visible instantly instead of being noticed on the next round.
• Less downtime: faster escalation measurably reduces unplanned stoppages.
• More visibility: everyone sees the same status – from operator to plant management.
• Data-driven improvement: the stored history reveals recurring bottlenecks and provides the basis for continuous optimization.

A digital Andon board in 5 steps

1. Define the relevant KPIs and fault cases.
2. Identify and connect data sources (PLC, OPC UA, MQTT, ERP).
3. Set thresholds and escalation logic.
4. Design the display for the shop floor and end devices.
5. Start a pilot, gather feedback, and roll out.

For the bigger picture, the guide 10 steps to digital shop floor management sets out the overall strategy. Background on the origin is provided by the description of Andon in the Toyota Production System.