What is an andon system?

Andon is a lean manufacturing concept originating from Toyota. It is a visual and audible notification system where operators signal for help when they encounter a problem. The word "andon" comes from Japanese paper lanterns. Modern systems use colored lights, displays, and sound alerts.

What is a good andon response time?

World-class response time is under 30 seconds. Good performance is under 60 seconds. Over 2 minutes indicates inadequate team leader coverage or poor system design. At Toyota, the expectation is that a team leader responds within one takt time cycle.

What is the in-station fix rate?

The in-station fix rate is the percentage of andon calls resolved before the work piece moves past the fixed position stop. A high rate (80%+) means most problems are solved quickly without stopping the line. Low rates indicate either complex problems or slow response.

How many andon calls per shift is normal?

It varies by industry and process maturity. Assembly lines may see 20-50 calls per shift. A very low number may indicate operators aren't pulling andon (bad culture). A very high number indicates process instability. Track trends rather than absolute numbers.

Should andon calls always stop the line?

No. The goal is to respond fast enough that the problem is resolved before a line stop is needed. Fixed position stops give the line a buffer — if the issue is resolved within the buffer time, the line continues. Only unresolved problems should cause a stop.

How do I build an andon culture?

Leadership must actively encourage andon use. Respond immediately to every call. Thank operators for pulling andon. Never blame operators for problems they identify. Make response resources available (sufficient team leaders). Track and act on andon data daily.

Andon Response Time Calculator

Calculate average andon response time from signal to resolution. Track escalation effectiveness and reduce production line stoppages.

Total Andon Calls

Total Response Time

min

Total Resolution Time

min

Fixed Without Line Stop

Measurement Period

shifts

Downtime Cost

$/min

Takt Time

sec

Escalation Calls

Avg Response Time

30 sec

Rating: World-Class — Target: <60 sec

Avg Resolution Time

1.5 min

Total 67.5 min across 45 calls

In-Station Fix Rate

80.0%

36 of 45 calls — Target: >80%

Line Stops

45 calls − 36 in-station fixes

Line Stop Cost

$4,050.00

9 stops × avg resolution × $300.00/min

Calls per Shift

9.0

45 calls ÷ 5 shifts

Escalation Rate

8.9%

4 escalated of 45 total calls

Potential Savings (95% fix rate)

$3,150.00

7 fewer stops at current resolution time

Performance Dashboard

Response Time

30sec (target: 60sec)

In-Station Fix Rate

80% (target: 80%)

Escalation Rate

8.9% (target: 10%)

Andon System Metrics Summary

Metric	Value	Target	Status
Avg Response Time	30 sec	< 60 sec	✓ On Target
In-Station Fix Rate	80.0%	> 80%	✓ On Target
Escalation Rate	8.9%	< 10%	✓ On Target
Calls per Shift	9.0	< 10	✓ On Target
Units Lost to Stops	9	0	✗ 9 lost

Andon Escalation Levels Reference

Level	Response By	Target Time	Trigger
Level 1 — Yellow	Team Leader	< 30 sec	Operator activates andon
Level 2 — Red	Group Leader	< 1 min	No L1 response within 30 sec
Level 3 — Line Stop	Supervisor + Maintenance	< 5 min	Cannot fix at station
Level 4 — Extended	Engineering / Management	< 15 min	Root cause investigation needed

Planning notes, formulas, and examples

About the Andon Response Time Calculator

An andon system is a visual signaling system that alerts team leaders and support personnel when a production line worker encounters a problem. The worker pulls a cord or pushes a button, triggering a light and/or sound that calls for help. The effectiveness of an andon system is measured by how quickly problems are responded to and resolved.

Fast andon response prevents small problems from becoming line stoppages. When response is quick (under 1 minute), many issues are resolved without stopping the line. When response is slow, operators either stop the line (reducing output) or let defects pass (creating quality problems).

This calculator computes key andon metrics: average response time, resolution time, calls per shift, and the percentage of calls resolved without stopping the line. Use it to benchmark your andon system effectiveness and identify improvement opportunities.

By calculating this metric accurately, production managers gain actionable insights that drive continuous improvement efforts and strengthen overall operational performance across the shop floor.

When This Page Helps

Andon response time directly impacts both quality and throughput. Every second of delayed response is a potential defect passed downstream or a line stoppage. Tracking these metrics drives faster response through accountability and proper staffing of support resources.

How to Use the Inputs

Enter the total number of andon calls during the measurement period.
Enter the total response time for all calls (sum of signal-to-acknowledgment times).
Enter the total resolution time for all calls (sum of acknowledgment-to-fix times).
Enter the number of calls resolved without a line stop.
Enter the measurement period in shifts.
Review average response time, resolution time, and in-station fix rate.

Formula used

Avg Response Time = Total Response Time ÷ Number of Calls

Avg Resolution Time = Total Resolution Time ÷ Number of Calls

In-Station Fix Rate = Calls Fixed Without Stop ÷ Total Calls × 100%

Calls per Shift = Total Calls ÷ Number of Shifts

Example Calculation

Result: 30 sec avg response, 80% in-station fix rate

Avg response = 22.5 min ÷ 45 calls = 0.5 min (30 seconds). Avg resolution = 67.5 ÷ 45 = 1.5 min. In-station fix rate = 36/45 = 80%. Calls/shift = 9. Response is fast (under 1 min target). Resolution could improve to reduce the 20% that cause line stops.

Tips & Best Practices

Target response time under 60 seconds — fast enough to prevent most line stops.
Place team leaders within line-of-sight or earshot of their team's andon signals.
Track response time by team leader to identify training or staffing needs.
Analyze repeat calls at the same station — they indicate unresolved root causes.
Never punish operators for pulling andon — it degrades the system if people fear using it.
Use andon data to prioritize improvement projects on the most frequent call stations.

Andon Escalation Tiers

Design a tiered escalation system: Tier 1 (team leader responds within 30 seconds), Tier 2 (supervisor joins at 2 minutes), Tier 3 (manager involved at 5 minutes). Automatic escalation ensures no call goes unresolved. Each tier has increasing authority to allocate resources.

Andon Data for Continuous Improvement

Andon calls are a goldmine of improvement data. Pareto charts of call reasons by station reveal the biggest opportunity areas. Track hourly call patterns to identify timing-related causes. Monthly andon analysis should drive the improvement project selection process.

Andon and the Respect for People Pillar

Andon embodies the Toyota principle of respect for people. It empowers every worker to stop production when quality is at risk. It provides immediate support when workers face problems. This mutual respect between management (providing resources) and operators (maintaining standards) is foundational to lean culture.

Sources & Methodology

Last updated: February 10, 2026

Frequently Asked Questions

Andon is a lean manufacturing concept originating from Toyota. It is a visual and audible notification system where operators signal for help when they encounter a problem. The word "andon" comes from Japanese paper lanterns. Modern systems use colored lights, displays, and sound alerts.