Comments on: Overburdened with Andon Calls http://theleanthinker.com/2010/01/20/overburdened-with-andon-calls/ Thoughts and insights from the shop floor. Wed, 08 Feb 2012 00:11:11 +0000 hourly 1 http://wordpress.org/?v=3.3.1 By: Bryan Zeigler http://theleanthinker.com/2010/01/20/overburdened-with-andon-calls/comment-page-1/#comment-34593 Bryan Zeigler Sat, 30 Jan 2010 22:30:47 +0000 http://theleanthinker.com/?p=1082#comment-34593 Great insights guys. Sometimes in striving for perfection I get lost from what is normal for the current state. Thanks again, Bryan Great insights guys. Sometimes in striving for perfection I get lost from what is normal for the current state.

Thanks again, Bryan

]]> By: Kris Hallan http://theleanthinker.com/2010/01/20/overburdened-with-andon-calls/comment-page-1/#comment-34582 Kris Hallan Fri, 29 Jan 2010 07:44:15 +0000 http://theleanthinker.com/?p=1082#comment-34582 By setting up your rules for andon pulling, you are basically setting up a continuous pareto. The problem with using a pareto to solve problems is that it is a batch and queue operation. You have to build up a batch of information before you can start solving the problems. This means all of the problems are old. By setting up standard rules for your andon that basically say, "when the problem is this big, do this", you get to work on the biggest problems. You CAN respond to every problem without causing muri because you get to define what a problem is. Even Toyota does not respond to EVERY problem. They just happen to be responding to problems that seem a lot smaller then the ones that we are resonding to. My factories andon will go off when someone is 30 minutes behind while Toyota's will go off when they are 30 seconds behind. They are not choosing to respond to the problem that made them 3 seconds behind however... I have found this to be a very effective way of setting inventory levels. Ask the team that will respond to problems how many andon calls they can physically respond to and solve to root cause in a week. Then set your abnormal inventory levels to hit that number of times based upon historic fluctuations. Then keep lowering waters as fluctuation decreases. By setting up your rules for andon pulling, you are basically setting up a continuous pareto. The problem with using a pareto to solve problems is that it is a batch and queue operation. You have to build up a batch of information before you can start solving the problems. This means all of the problems are old. By setting up standard rules for your andon that basically say, “when the problem is this big, do this”, you get to work on the biggest problems.

You CAN respond to every problem without causing muri because you get to define what a problem is. Even Toyota does not respond to EVERY problem. They just happen to be responding to problems that seem a lot smaller then the ones that we are resonding to. My factories andon will go off when someone is 30 minutes behind while Toyota’s will go off when they are 30 seconds behind. They are not choosing to respond to the problem that made them 3 seconds behind however…

I have found this to be a very effective way of setting inventory levels. Ask the team that will respond to problems how many andon calls they can physically respond to and solve to root cause in a week. Then set your abnormal inventory levels to hit that number of times based upon historic fluctuations. Then keep lowering waters as fluctuation decreases.

]]> By: Il meglio della blogosfera lean #22 — Encob Blog http://theleanthinker.com/2010/01/20/overburdened-with-andon-calls/comment-page-1/#comment-34564 Il meglio della blogosfera lean #22 — Encob Blog Sat, 23 Jan 2010 07:31:51 +0000 http://theleanthinker.com/?p=1082#comment-34564 [...] Overburdened with Andon Calls dal blog The Lean Thinker di Mark Rosenthal: Una bella riflessione su andon, lavoro standard e rispetto delle persone (traduzione automatica) [...] [...] Overburdened with Andon Calls dal blog The Lean Thinker di Mark Rosenthal: Una bella riflessione su andon, lavoro standard e rispetto delle persone (traduzione automatica) [...]

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