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With training and red bins at each station, we spent less time processing pieces that were already defective—we pulled them out earlier. But sometimes defects still slipped through because workers weren't always sure if something was a defect, or they hesitated to stop the line. So we still had a mix of caught defects and mistakes.
Andon is a signal that something is wrong and help is needed. When a worker isn't sure, they shouldn't have to guess alone. We introduce an andon: when a worker identifies a possible defect (that would go to the red bin), they can call for the Team Leader (TL). The station pauses, the TL comes over, and with their deeper knowledge of the process they help decide: fixable (revert to good) or defective (to red bin). So we don't push uncertainty downstream—we stop and resolve it. The change we make: enable andon at stations and show the TL responding; the line can pause briefly so we get the right decision instead of guessing.
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