Andon escalation system decision tree

WHO RESOURCES AVAILABLE TO SOLVE THE PROBLEM ACTION IF

WHAT QUESTION ASKS? EXAMPLES CRITERIA AT THIS LEVEL ANSWER IS YES

part shortage, information is missing or Quality standards - visual boards

unclear, machine or tool down or
Do I have a problem? Worker Potential defect Standard operating procedures Call line focal
missing, defective parts, cannot
accomplish work tasks within takt time
Job specific paperwork
Basic skill training Call area lead, and
Is this really a Defect cannot be fixed
Line focal staff shortage, turn Andon cup to
problem? within 1 takt In-line people power YELLOW

In-area people power

Advance skill training/alternate methods Call Production

Is this a systemic Defect cannot be fixed
Area Lead Lead and turn
problem? within 3 takt Production system information (console) andon cup to RED

Machinery repairs under $500

In-production people power and Overtime up to 5%
Is this problem "Line stop team"
going to put Defect cannot be fixed so
Production Call the Operations
our costs over that the job will remain on Material replacement up to $200 per job, or 1% of mtrl budget
lead manager
budget for the budget or schedule
Supply chain schedule tweaks of 3 days or less
job?
Operating system information (Syspro)

Machinery repairs or purchases of $5,000 or less

Temporary labor assistance and Overtime up to 10%

Is this Manager's of "line stop team"

problem Material replacement up to $200 per job, or 10% of mtrl budget
going to put Defect cannot be fixed so
Operations Call the General
our costs that the week will remain Supply chain major schedule reprioritization
Manager Manager
over budget on budget or schedule
Expedited freight of $500 or less
for the
week? Business system information (financial)

Client reprioritization within operating agreements

Machinery repairs, or purchases as necessary

In-company people power and overtime as necessary

Is this
problem Management team
going to Material replacement as needed
put our Defect cannot be fixed so
General
costs that the Month will remain Supply chain - GM level assistance, and inventory strategies Notify the President
Manager
over on budget/schedule
budget Expedited freight as necessary
for the Enterprise system information
month?
Client reprioritization outside of operating agreements
1 Worker: Do I have a problem? (speed, quality, question on how to make it etc...)

2 Line lead: Is it really a problem or not? (Cancel or not cancel)

3 Manager: (once the line stops - "Will it take more than 2 Takt
Times to solve the problem?")

4 Managers Manager (one off or systemic?)

1st Responder - Area lead

Don't Escalate - If within lead/teams control
Scheduling - Moving capacity between groups but still hitting BOO
Quality issue, fixed within cycle time

Escalate to 2nd Responder- If Outside lead/teams control

One unit in 'Red' for any reason
Can't meet loaded, daily schedule due lost capacity or just behind schedule
Material shortages or defects outside your control
All Line stoppers including flow /pull issues between departments

2nd Responder - Production lead

Don't Escalate - If within lead/teams control
Any issue fixed within cycle
flow /pull issues between production departments
one unit in 'Red' for any reason but second unit blue
quality issues that require rework but no additional materials

Escalate to 3rd Responder- If Outside lead/teams control

Material issues (not here when job starts, poor quality, quantity wrong)
BOM/BOO accuracy
Behind schedule for the day or need for OT
2 consecutive in 'Red'
Console issues
Rework issues that require the purchase/ use of additional inventory
Machine down conditions

3rd Responder - Production lead

Don't Escalate - If within lead/teams control
Material issues (not here when job starts, poor quality, quantity wrong) - work with purchasing/ scheduling
BOM/BOO accuracy - work with PD
Machine down conditions- less than $500
Less than 2 in 'Red" with a fix to get back to cycle/ BOO
Console issues - Jeremy