ANDON is a CALL system, when issue happened in production line, operators can pull rope, or press button to call supervisor or engineers to fix issue. ANDON system includes Call module, Notification module,
Analysis module. ANDON integrates with PMC(Process Monitoring),
AVI(Automatic Vehicle Identification), EPS(Error Proofing).
ANDON Types: Quality Call Equipment CallMaterial Call EPS Call System Call Shift Call
ANDON PLC
MES
Equipment PLC
ANDON SERVER
Equipment PLC
1 Quality Call
2Equipment Call
3Material Call
4 EPS Call
5 System Call
6Shift Call
Quality Call Occurs when Operator finds Quality Issue during operation, and needs help(from leader or engineer).
Trigger method:Operator pulls Rope or pushes Button, and then sends signal to ANDON PLC OPC ANDON Server.
ANDON PLC
MES
Rope
ANDON Server
OPCServer
Remote I/O
CP Card
IT Network
Control Network
Quality Call
Quality Call
Equipment Call
Equipment Call is triggered by Equipment Fault automatically.
Equipment PLC sends Faults or Errors to ANDON PLC OPC ANDON Server.
ANDON PLC
MES ANDON Server
OPC Server
Remote I/O
CP Card
IT Network
Control Network
Equipment PLC
COUPLER
Equipment Call
Material Call
Material Call Occurs when Operator finds a material shortage, and requires to get it delivered in time.
Trigger method: Operator pushes Call Button,
and sends signal to ANDON PLC OPC ANDON Server.
Button
Material Call
ANDON PLC
MESANDON Server
OPCServer
Remote I/O
CP Card
IT Network
Control Network
EPS Call
EPS(Error Proofing System) Call is triggered by an Error Proofing failure.
2 Inputs:1. For PLC-Control Machines such as
Filling Machine, Failure signal is sent to ANDON PLC via Coupler.
2. For PC-Control Machines such as Nut Runner, Failure signal is sent to ANDON PLC via OPC.
2 Outputs:1. ANDON PLC notifies Conveyor Stop.2. ANDON PLC syncs Calls to ANDON
Server for further analysis.
ANDON PLC
MESANDON Server
OPC Server
CP Card
IT Network
Control Network
Equipment PLC
COUPLER
Controller
Nut Runner
Equipment Server
Conveyor PLC
COUPLER
OPC Server
Failure
Command
Command
CP Card
Failure
System Call
System Call is triggered by system verification failure or system exceptions, such as AVI identification failure Call.
Example:MES reads RFID Tag via Conveyor PLC, when verification failed, then MES sends error message into Conveyor PLC via OPC, and then forwards it to ANDON PLC ANDON Server.
ANDON PLC
MESANDON Server
OPC Server
CP Card
IT Network
Control Network
Coupler
Conveyor PLC
CP Card
ERROR
Shift Call
Shfit Call is triggered by Factory Calendar automatically.
MES sends shift information into ANDON Server, and then to ANDON PLC via OPC.
ANDON PLC
MESANDON Server
OPC Server
CP Card
IT Network
Control Network
Shift Information
Level Description
Normal Production line & Equipment is running normally.
Info Information, e.g. Shift Change
Alarm Alarm
Error Error & Fault
E-Stop Emergency Stop
Stop Stop
Offline Equipment is offline
Maintenance Equipment is under maintenance
Break Break
2 Categories:1) Issue, e.g.
Alarm/Error.2) Reference, e.g. Info/Break. Level definition is
shared with PMC module.
ANDON PLC outputs light signal to LAMP.
ANDON PLC outputs music signal to Player & Speaker.
ANDON PLC maps data into ANDON Board via SCADA software.
ANDON PLC
MES ANDON SERVER
OPC Server
Remote I/O
CP Card
IT Network
Control Network
LampSpeaker
ANDON Board
Driver
LAMP
Level Quality Call Equipment Call Material Call EPS Call System Call Shift Call
Normal
Info
Alarm Yellow/Blink Yellow/Blink Yellow/Blink Yellow/Blink
Error Red/Blink Red/Blink Red/Blink
E-Stop Red/Blink
Stop Red/Keep
Offline
Maintenance
Break
Speaker
Level Quality Call Equipment Call Material Call EPS Call System Call Shift Call
Normal
Info Play Music
Alarm Play Music
Error Play Music Play Music Play Music
E-Stop Play Music
Stop Play Music
Offline
Maintenance
Break
Board
Level Quality Call Equipment Call Material Call EPS Call System Call
Shift Call PMC Block
Normal Green
Info Show Text Show Text
Alarm Yellow Yellow Yellow
Error Red Red Red Red
E-Stop Red Red
Stop Red Red
Offline Gray
Maintenance Gray
Break Gray
Log data for root cause analysis.
Summary report for bottle neck analysis.
Data source of OEE report.