P 13716 Andon System for Toyota Production Systems

P 13716: Andon System for Toyota Production Systems Lab Project Objective: The objective of this project was to introduce Jidoka to the four-station assembly line within the Toyota Production Systems Lab at the Rochester Institute of Technology. Background Information: Jidoka is a term used in the Toyota Production System that refers to diagnosing an abnormality immediately and correcting it accordingly so that defects are not passed along to the next operator. An Andon system is the visual and audial signaling system of Jidoka. Project Description: In order to improve quality on this line, two Andon systems and a corresponding monitoring system were developed. Mechanical Andon Systems: Electrical Andon System with Monitoring: • • Design Specifications Includes paced line capability Global display tracks station status 3 activation modes, green, yellow and red Each station accommodates NTID needs • • Andon System Particulars: Team Member recognizes abnormality and presses button. Button press triggers an automated response from the Programmable Logic Controller (PLC). PLC program assesses station status and operates station lights accordingly. Lab. VIEW interfaces with PLC to display real-time data regarding the statuses of stations. Data mining capabilities created to promote future root cause analysis and preventative countermeasure development. Design Specifications: Visible from 30 feet Inexpensive Simplistic design for ease of use Accommodate additional stations Andon System Particulars: • Team Member recognizes abnormality and initiates visual cue (colored cone or colored magnet). • Team Member subsequently initiates auditory cue (voice alert or bell). • The combination of cues prompts Team Leader to visit given station. Project Team: Trevor Andrews Holli Monroe Emily Piccione William Wright Industrial & Systems Engineering Mechanical Engineering The project team would like to acknowledge and express appreciation to RIT faculty member Scott Bellinger for all of his help and assistance in executing this project. More information can be found at the following website: http: //edge. rit. edu/edge/P 13716/public/Home