Andon System
Industrial Andon hardware & real-time Andon monitoring software.
The Robato Systems Andon System is a complete hardware + software solution designed to reduce downtime, accelerate issue escalation and improve operator–supervisor communication on the shop floor. Using LED Andon display boards, Andon tower lights, push-button stations, wireless call buttons and Andon monitoring software, the system provides instant visibility of issues across machines.
The Andon system on one machining line
What is an Andon System?
It signals problems such as
- Machine breakdown
- Material shortage
- Quality issues
- Operator call for help
- Changeover request
- Safety / emergency events
When an operator presses the Andon button or tower light switch, alerts are instantly shown on
- LED Andon Display Boards
- Andon Tower Lights
- Production Dashboards
- Smart TVs
- Supervisors' mobile phones
Andon Tower Device & Tower Stack Light In 4 and 5 button kits
4-Button Andon Tower Device
Four call buttons on a wireless call box, cabled to a four-tier LED stack light — the core machine statuses for any station.
- Call buttons
- Fault, Maintenance, Running, Idle
- Stack light
- 4 tiers: red, amber, green, blue
5-Button Andon Tower Device
The same kit with a dedicated Quality button and a fifth, clear tier — for lines that check quality at the station.
- Call buttons
- Fault, Maintenance, Running, Idle, Quality
- Stack light
- 5 tiers: red, amber, green, blue, clear
The calls
- Fault
A breakdown or stoppage. The red tier lights and the call goes straight to maintenance and the supervisor.
4 and 5 button
- Maintenance
Planned work, a tool change or a repair under way. Amber tells the floor the stop is known and being handled.
4 and 5 button
- Running
The machine is back in production. Green is the all-clear anyone on the floor can read at a glance.
4 and 5 button
- Idle
Waiting on material, an operator or the next job. Blue keeps idle time apart from breakdowns in the downtime log.
4 and 5 button
- Quality
A quality check is needed at the station. The clear fifth tier brings an inspector before parts move on.
5 button only
What's in the kit
LED tower stack light
Four or five stacked LED tiers, one per status, raised on a pole clear of the machine — so a station's state reads from across the floor, without walking over to ask.
Colour-coded call buttons
Every button is labelled and matched to its tier: Fault in red, Maintenance in amber, Running in green, Idle in blue and, on the 5-button kit, Quality. The right call is a single press — no screen, no menu.
Wireless call box
An antenna on the call box sends every press, time-stamped, to the Andon monitoring software, LED Andon boards and supervisors' phones — without running network cable across the shop floor.
Pole and bracket mount
The stack light stands on a pole with an L-bracket that fixes to a machine, bench or line-side frame, so the light sits high and stays put.
Long connecting cable
A long cable joins the tower to the call box: mount the light up high where everyone can see it, and keep the buttons within the operator's reach.
Plug-in power adapter
Each kit runs from its own plug-in power adapter. Mount it, plug it in, and the station is ready to raise its first call.
Robato Andon Hardware Components
LED Andon Display Boards
Large LED boards that show live machine status, call alerts and downtime reasons.
- Single-line and multi-line designs
- Red, Green, Amber, RGB configurations
- Supports WiFi / Ethernet updates
- Custom board sizes available
Andon Tower Lights
Industrial stack lights with Red/Yellow/Green signals for visual alerts.
- Wired or wireless communication
- 3-color and 5-color options
- Direct PLC control or manual buttons
Andon Push Button Stations
Simple and robust operator buttons for calling maintenance, QA or supervisors.
- Single button / multi-button stations
- Wired / wireless
- Wall-mount or machine-mount options
Wireless Andon Call Device
Battery-powered, long-range wireless call buttons for flexible deployment.
- Battery-powered operation
- Long-range wireless
- Flexible deployment
Smart Production Counters Integration
Production counters automatically trigger Andon events for:
- Downtime detection
- Low performance alerts
- Quality / rejection spikes
Andon Monitoring Software
Deployment
- Cloud
- On-Prem
- Hybrid
Key features
Real-Time Alert Dashboard
See all active Andon calls instantly.
Escalation Tracking
Auto-escalation if an issue is not acknowledged.
Downtime Logging
Machine breakdown and reason capture.
Response Time Monitoring
Track how fast supervisors respond.
Operator–Supervisor Communication
Seamless communication between teams.
Shift & Team Performance
Compare performance across shifts.
Smart TV Display Support
For large-area visibility.
How the Andon System Works Four hand-offs, every one time-stamped
Shop floor
Signal
An operator presses an Andon push button or tower light switch — or a PLC raises the signal itself — and the Andon controller picks it up instantly.
Push buttons / tower lights → Andon controller
Line side
Display
The controller pushes the alert to LED Andon boards and Smart TV displays, so everyone on the floor sees which machine needs help — and why.
Andon controller → LED Andon Board / Smart TV
Software
Record
Every event lands in the Andon monitoring software — cloud, on-prem or hybrid — building a live log of calls, downtime reasons and responses.
Andon controller → Cloud or On-Prem Monitoring Software
Supervisors
Respond
The right supervisor is alerted on the dashboard or their phone, with auto-escalation if an issue is not acknowledged.
Supervisors receive alerts instantly on dashboard or mobile
Technical Specifications
- Communication
- Wired, Wireless, WiFi, Ethernet
- Display Types
- LED Andon Boards, Tower Lights, Smart TV Dashboards
- Inputs
- Push buttons, tower light switches, PLC signals
- Software
- Cloud / On-Prem / Hybrid
- Alerts
- Visual, Audio, SMS/Email (optional)
- Integration
- Production counters, Downtime monitoring, OEE system
Industries Using Andon Systems
Automotive OEMs & Tier-1 suppliers
Pharmaceutical production lines
Textile weaving / knitting / garment factories
Electronics & PCB assembly
FMCG / Food / Packaging plants
General engineering & machining
Upgrade to a Smart Andon System for Faster Issue Escalation
Frequently Asked Questions
An Andon System is a real-time alert and escalation system used in factories to signal issues, downtime or quality problems using buttons, tower lights and display boards.
Yes, Robato offers wired and wireless Andon systems using WiFi and Ethernet-enabled devices.
Yes. Andon events can be linked with production counters and downtime monitoring software for complete visibility.
Yes. Robato provides Cloud and On-Prem Andon Monitoring Software with dashboards for issue tracking, downtime logs and operator responses.
Yes. Andon alerts can be displayed on LED Andon boards, Smart TVs, large displays or production dashboards.
Put every stoppage on the board
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