ANDON暗灯系统实用教案.ppt

1第1页/共85页第一页，共86页2Table of Contents 目录GM-GMS Relationship 全球制造体系(tǐxì)的内部联系Definition 定义Purpose 目的Core Requirements 核心要求Benefits 益处Andon Enablers 暗灯驱动因素Process Overview: 过程概要 Andon Components 暗灯的组成 Andon Pull cord and Switches 暗灯的拉绳和开关 Visual & Audio Signals 目视和声音信息 Andon Boards 暗灯板 Conveyor Line Layout 传动链布局 System Operation 系统运行 How to Use the Andon System 如何使用暗灯系统Roles&Responsibilities 角色和责任Summary 总结Appendix:References 附录：参考资料Appendix:Revision Log 附录：审核日志第2页/共85页第二页，共86页。

3GM-GMS Relationship 全球制造全球制造(zhìzào)体系的内部联体系的内部联系系The GM-GMS Operating Guideline#29.0 Andon System, supports the GM-GMS Principle of Continuous Improvement in contributing to the Business Goals.GM-GMS#29.0操作指引“暗灯系统(xìtǒng)” 支持GM-GMS“不断改进”原则，有助于制造系统(xìtǒng)五个目标的实现第3页/共85页第三页，共86页4Definition 定义定义(dìngyì)The Andon System is an operational floor process control system that can be activated manually or automatically to communicate the need for assistance when abnormal conditions occur, as well as to communicate other relevant information.暗灯系统是流水线操作过程控制系统，当出现异常状况时，通过(tōngguò)手动或自动激活系统来寻求帮助以及交流其他相关的信息。

第4页/共85页第四页，共86页5Purpose 目的目的(mùdì)The purpose of the Andon System is to: 暗灯系统的目的就是：Empower operations to prevent the occurrence or passing of defects to the next process.使操作过程能够防止缺陷(quēxiàn)产生或流入下一道工序Call for assistance when behind in the work sequence or an out of standard condition occurs.当跟不上工作流程或有非标准的状况产生时，寻求帮助Initiate the problem solving process. 促使解决问题流程的实施Drive management and support groups to “Go and See” the problems on the floor and take action.推动管理层和支持工段“巡视发现”生产线上的问题并采取行动Collect data, identifying where problems occur most frequently.搜集数据，识别问题发生最多的地方Communicate operational status information. 传递操作中的状态信息第5页/共85页第五页，共86页。

6Andon Core Requirements 暗灯核心暗灯核心(héxīn)要求要求1 The Andon System: 暗灯系统a) visually displays relevant information for anyone to see and quickly recognize the problem. 目视化显示相关信息使每个人都看见，并迅速确认问题b) Interlocks to tooling, equipment and manual activation 和加工工具、设备和手动操作相互关联c) has the capability to stop the moving line process at the FPS, except in emergency cases 紧急情况下，在固定(gùdìng)停止位阻止生产线的移动d) consists of a single pull cord/push button system, easily accessible to the operator 由简单的拉绳/按钮系统组成，方便操作者使用e) directs the support organization to “Go and See”the problems 指导支持团队“巡视发现”问题f) provides feedback to the source from quality checks, inspection and repair stations 把质量检查、审核和返修工位的信息反馈回问题的源头g) provides information to the maintenance organization to respond 向维修工段提供信息使其及时响应h) signals people to perform standard/routine activities 提醒员工进行标准/常规的活动i) provides data(pulls and line stop time)by established Andon zone to problem solve bottlenecks and problem areas 通过暗灯区域的数据(拉动和停线的时间)显示问题解决的瓶颈以及问题所在区域j) is flexible enough to incorporate other visual management needs as they arise 有很大的弹性，可以融入其他的目视化管理需求第6页/共85页第六页，共86页。

72 A people support/team concept structure must exist that has clearly defined roles and responsibilities as the job relates to the production floor(team leader, group leader, production leadership, maintenance,personnel, engineering,quality, materials,other). 必须有一员工支持/团队概念体系，清楚地定义与生产线相关的所有工作的角色和责任(班组长，工段长，生产领导层，维修，人事，工程，质量，物料，及其他)3 Standardized Work is clearly documented and followed. 标准化操作明确地整理成文，并予以执行4 Quality Standards and Process Controls are defined for each job. 每个工位的质量标准和过程控制都有定义5 The Andon System is used to achieve the concept of “Do not accept, build, or pass a defect”. 使用暗灯系统来达到“不接收，制造，或传递缺陷”的思想观念6 The Problem Solving Process is used to resolve recurring Andon calls. 使用问题解决流程来消除重复的暗灯呼叫(hū jiào)7 Actual takt time (conveyor speed)is established to allow for proper use of the Andon System. 建立实际单件工时(传动链的速度)，合理利用暗灯系统8 Decoupling exists to allow for the proper use of the Andon System. 退耦(装置)的存在使得要合理利用暗灯系统第7页/共85页第七页，共86页。

8Benefits 益处益处(yì chu)The Andon System supports continuous improvement in Safety,People,Quality, Responsiveness, and Cost.暗灯系统支持在安全、人员、质量、响应和成本方面的不断改进Andon is used as a formal communication tool to alert the organization to “Calls for help” and abnormal process conditions.An Andon response process should be in place to support and rectify situations as quickly as possible.暗灯作为一种正式的交流工具，警示相关部门寻求帮助以及有异常的流程状况发生而设置暗灯响应流程为了尽快支持并纠正相关状况Andon boards for all areas are easy to understand and support”Status at a Glance”每个区域的暗灯板都容易理解并“一目了然”Andon area configurations are established to direct the support organizations to “Go and See”the problems on the floor.暗灯区的布局可以指导支持工段巡视(xúnshì)并发现流水线上的问题Andon is flexible in order to incorporate improvements and required changes as they arise.为了融入不断改进和所要求的变化，暗灯设计是柔性的。

Andon collects data for problem solving and identifying where problems occur most frequently.暗灯搜集解决问题的数据并识别问题发生最多的区域Andon can remind employees to perform routine activities at regular intervals.暗灯可提醒员工定时进行常规活动Empowers team members to Build Quality in Station 使得员工在每个工位制造质量Andon is a tool to keep the line running! 暗灯是保持流水线运行的工具第8页/共85页第八页，共86页9Andon Enablers 暗灯的驱动暗灯的驱动(qū dònɡ)因素因素Below are the enablers that should be in place prior to activating the Andon System.以下是在使用暗灯系统前需要合理设置的驱动因素Continuous Improvement Culture 不断改进的氛围Management Commitment 管理层的义务Teamwork 团队合作Employee Training 员工培训Defined Quality Standards 定义过的质量标准Level Scheduling 同步的计划Fixed Position Stop 固定停止位Decoupling/Buffers 退耦(装置)/缓冲Standardized Work(Key Point:avoid operation interference and downtime by reducing or eliminating layer builds on adjoining processes)标准化操作(关键点：在相邻的工艺流程减少或消除叠层制造，以避免操作的互相影响以及停线)Standardized Problem Solving 标准化问题解决流程 Address System 定位系统Capable Process&Equipment 可行(kěxíng)的工艺和设备Mutual Trust&Respect 互相信任和尊重第9页/共85页第九页，共86页。

10Andon Components 暗灯组成暗灯组成(zǔ chénɡ)Workstation Addresses 工位的位置Pull Cords,Buttons,and Switches 拉绳，按钮和开关Lights 亮灯Audio Signals and Speakers 声音(shēngyīn)信号和扬声器Andon Boards 暗灯板第10页/共85页第十页，共86页11Andon boards,workstation lights and speakers provide alerts to the team leader, group leader, maintenance team member, and management so they can respond quickly to “Calls for help”.暗灯板、工位灯和声音装置可以提醒班组长、工段长、维修员工和管理人员对于“寻求援助的需求(xūqiú)”迅速响应Andon System Layout for a Moving Line 流水线的暗灯系统流水线的暗灯系统(xìtǒng)布局布局第11页/共85页第十一页，共86页。

12Pull Cords, Buttons and Switches 拉绳、按钮和开关拉绳、按钮和开关(kāiguān)The Andon system can be activated by a number of different methods.This chart describes the propose and use of the different pull cords,buttons,and switches of the Andon system.有几种不同的方式激活暗灯系统图表描述了暗灯系统不同拉绳、按钮和开关的目的(mùdì)及使用第12页/共85页第十二页，共86页13Activation Device激活激活(jī huó)设备设备Purpose目的目的(mùdì)Where Used使用使用(shǐyòng)的地方的地方Description描述Andon Pull Cord暗灯拉绳Andon Push Button暗灯按钮Run Stop Switch运行停止开关Manipulator Over-Travel Limit Switch操作者超程限制开关Team Member Help Call组员帮助响应Team Member Help Call组员帮助响应Stop the process or conveyor immediately for safety reasons为了安全原因，立即停止流程或传动链Increase level of safety on the workstation by stopping the conveyor when an over-travel condition occurs.当出现超程情况，停止传动链以提高工位的安全性On a workstation in a moving conveyor line移动的传动链上的工位Work Cells,such as a Body shop or Press Line,or in a Paint Booth工作间，如车身或冲压线，或在油漆房Installed along the conveyor and on all major equipment沿传动链在主要设备旁安装The limit switch is installed along the travel of the manipulator限制开关在操作者行进路程旁安装Connected to a switch with a light and looped along the length of the conveyor亮灯和开关连接，沿传动链形成环路Switch box with a push button is located in the most convenient location of the work cell有按钮的开关盒处于工作间最方便操作的地方Placed at regular Fixed Position Stops on alternating sides of the line.(Note:Must be in accordance to all safety standards and regulations.)的两旁交替放置于固定停止位处(注：必须符合所有的安全标准和规定)To prevent manipulators,articulating arms and assist devices from dangerous over-travel conditions to increase safety on the workstations.避免操作者、连接设备和辅助仪器发生危险的超程情况，提高工位的安全性。

第13页/共85页第十三页，共86页14Pull Cords, Buttons and Switches 拉绳、按钮和开关拉绳、按钮和开关(kāiguān)第14页/共85页第十四页，共86页15Activation Device激活激活(jī huó)设备设备Purpose目的目的(mùdì)Where Used使用使用(shǐyòng)的地的地方方Description描述Critical Check Complete Button&Light关键检验完成按钮和亮灯Local Quality Call Buttons区域质量响应按钮 Downstream Quality Call Buttons 下道工序质量响应按钮 To indicate Critical Checks have been completed表示关键检查已完成To call Production Team Leader to the Quality Verification Station呼叫班组长到质检工位To call the Production Group Leader to the Quality Verification呼叫生产工段长到质检工位Switches installed in Zone area or as needed to support the process开关安装在需要的区域，支持工艺流程Quality Verification Stations质量检验工位Quality Verification Stations质量检验工位The button light turns on indicating that a check must be done.After the button is pressed,the system turns off the light button,acknowledging the check has been completed.If the Team Leader does not press the button by the time the check time expires, the button-light flashes.灯亮表示必须检查。

按下按钮后，系统关闭亮灯，表示检查完成如果班组长在检查时间结束时，没有按下按钮，亮灯将闪烁Push button switch mounted on a pedestal按下装在支架台上的开关按钮Push button switch mounted on a pedestal按下装在支架台上的开关按钮第15页/共85页第十五页，共86页16Visual and Audio Signals 目视和声音目视和声音(shēngyīn)信号信号Visual Signals 目视信号目视信号Standard colors help determine the “Status At A Glance”颜色标准帮助确定状态颜色标准帮助确定状态Green signals “OK”or Normal Status绿色表示绿色表示OK或正常状态或正常状态Yellow signals “Help Required”Potential Risk of Loss of Production or Quality.黄色表示需要帮助，生产或质量黄色表示需要帮助，生产或质量(zhìliàng)有潜在损失的风险有潜在损失的风险Red signals “Line,Process Or Equipment Is Down”-Immediate Help Is Required.红色表示生产线、流程或设备的停止红色表示生产线、流程或设备的停止-需要立即抢修需要立即抢修(In some applications of Andon it may be necessary to use other colors to fulfill all the requirements of the system.)在暗灯的有些使用中，需要应用其他颜色来满足系统的所有要求在暗灯的有些使用中，需要应用其他颜色来满足系统的所有要求第16页/共85页第十六页，共86页。

17Audio Signals 声音信号Audio signals convey a unique melody or audio signal to alert the correct support personnel to look up at the Andon Board or to see the workstation lights to determine the specific location calling for help.声音信号发出独特的音乐或声响来提醒纠正支持人员观察暗灯板或工位亮灯以确定(quèdìng)需要帮助的特定工位Typically two types of audio signals are used: 使用的两种典型的声音信号： Melodies 音乐 Tones 音调Unique melodies are used to distinguish different Andon events,Groups,Andon Zones,and routine reminders.独特的音乐用来区分不同的暗灯事件、工段、暗灯区域以及日常的提示Tones are used for common Andon alerts,such as equipment faults and scheduled start or stop of the line.声调是用来常规的暗灯提醒，如设备故障，生产线的启动或停止。

第17页/共85页第十七页，共86页18Andon Lights 亮灯亮灯Activation Device激活激活(jī huó)设备设备Purpose目的目的(mùdì)Where Used使用使用(shǐyòng)的地的地方方Description描述Workstation Light工位灯Run stop light运行停止灯Equipment Fault light设备故障灯 Supports help call function寻求帮助功能Support Run stop function运行停止功能Support equipment faults显示设备故障One Yellow workstation light is located at the end of each workstation.每个工位的末端有一黄色的灯One red beacon light is located at the run stop switch在运行停止开关处有一红色的信号灯One red beacon light is located at the control panel of each piece of major equipment在每个主要控制设备的面板上有一红色的信号灯Turns on solid yellow in a response to a call for help.Flashes when the vehicle reaches the fixed position stop.寻求帮助时显示常黄。

当车辆达到固定停止位就闪烁When run stop switch is activated, the light flashes.运行停止开关激活时，亮灯闪烁When an equipment fault occurs,it flashes设备发生故障，灯就闪烁第18页/共85页第十八页，共86页19Audio Signals and Speakers 声音声音(shēngyīn)信号和扬声器信号和扬声器The Andon system will play unique audio signals such as, melodies and tomes for specific types of help calls and faults.It should be user friendly and flexible to allow for the following functions:暗灯系统会发出独特的声音信号如，求助和发生故障的特定类型的音乐和声调系统具有以下(yǐxià)功能，对使用者友好并具有弹性： Length of Time On 声音的长短 Fast Mode of Play (25% to 100% Faster than Original) 播放的快速模式(比开始快25%到100%) Priority level assignment for event melodies and tones 音乐和声调的优先级分配 Selectable Location of Melody Play (Zone,Board or both) 可供选择的播放音乐(区域，显示板) Capable of supporting all Andon Calls and Faults with a specific Melody or Tone 用一特定的音乐和声调支持所有的暗灯求助或故障情况 Adjustable speaker volume 可调节的声响第19页/共85页第十九页，共86页。

20Speakers are placed to ensure Team Leaders and Group Leaders and all other responders hear the melodies.Speaker placement is especially crucial for louder facilities.放置扬声器是确保班组长，工段长以及(yǐjí)其他所有响应者听到音乐扬声器的放置对于有噪声的设备十分重要第20页/共85页第二十页，共86页21Andon Boards 暗灯板暗灯板Different Types of Andon Boards (all boards may not be required to fulfill the core requirements of Andon)不同类型的暗灯板(所有的暗灯板不一定都要满足(mǎnzú)暗灯的核心要求)Group Boards 工段板Supports a specific group of operations or production area,usually one group leader’s area支持一特定工段的操作或生产(shēngchǎn)区域，通常是工段长区域Shop Status Board 车间状态板Supports the organization and provides real-time status and performance information of the current shift.提供当前班次的实时状态和绩效信息第21页/共85页第二十一页，共86页。

22Performance Board 绩效板Supports the Production team leaders and group leaders by providing real-time pull count and downtime information by Zone for the current shift.提供当前班次各个(gègè)区域的拉灯次数及停线信息，支持生产班组长和工段长Final Process Board 最终工艺板Supports the Production and Quality Organizations by providing quality and throughput information and informs them where help is requested支持生产部门和质量部门，提供质量和产量信息并告知需要帮助的地方Maintenance Board 维修板Supports the Maintenance organization by providing information related to abnormalities with equipment and informs them where help is requested.提供设备异常的相关信息，支持维修部门并告知需要支援的地方第22页/共85页第二十二页，共86页。

23Group Board 工段工段(gōngduàn)板板The Group Board supports a specific group of operations,conveyor length or production area, usually one group leader’s area.The appropriate light is turned on and melody is played to alert support personnel when help is requested or a fault occurs.工段板是对一个特定工段的操作，传动链或生产区域，通常是工段长区域的支持当需要帮助或发生故障时，相关的灯亮，音乐响起提醒支持人员Because of different process requirements,group sizes,and board locations for each department, the boards may vary slightly from department to department.由于不同的工艺需要、工段大小和位置，每个工段的暗灯板略有区别Smaller size boards can be used where team members are working in isolated work cells as long as they retain the common functionality requirements.员工在单独的工作间里操作时，可使用较小尺寸的暗灯板，只要符合通常的功能要求。

It should also be recognized that in other work cell applications of the Andon system such as a stamping process, the group boards may look different from what we would see in a typical moving line operation.These boards would be more focused on cell calls and equipment faults,but the intent of the system must stay true to the core requirements of Andon.必须指出，在其他工作间使用的暗灯系统(xìtǒng)，如冲压流程，工段板和运行的流水线操作的工段板是不同的这些板更注重于工作间的求助及设备故障，当然系统(xìtǒng)的内容必须符合暗灯的核心要求第23页/共85页第二十三页，共86页24第24页/共85页第二十四页，共86页25Shop Status Board 车间车间(chējiān)状态板状态板Supports the organization and provides real-time status and performance information for the current shift.提供当前班的实时(shí shí)状态和绩效信息The location of the board is typically at the end of a shop, or at the Visual Management Center where all team members can obtain status information quickly.板的位置通常在车间的末端，或在目视化管理中心，所有的员工可以迅速得到状态信息。

第25页/共85页第二十五页，共86页26Line 生产线生产线Condition 情况情况(qíngkuàng)Shop Status车间(chējiān)状态Area or Line Status区域(qūyù)或生产线状态Starved/Blocked短缺/堵塞Total Downtime Area/Line总的停线时间Key Production Information &Counts关键生产信息及数量Green-OK-Line is running 绿色-生产线运行正常Red-Not OK.Line is not running. 红色-生产线没有运行FA：Float Alarm:Yellow Solid Level 2 Alarm Yellow Flashing Level 3Alarm缓冲警示：黄灯常亮 2级警示，黄灯闪烁3级警示Green-OK-Line is running 绿色-生产线在运行Red-Line is down for Andon Call or Equipment 红色-由于暗灯或设备的原因停线Green-OK 绿色-OKStarved/Blocked-Red 红色-短缺/堵塞Total Area or Line downtime总的区域或生产线停线时间Current Shift Production Information-Goal,Actual,Trend,Quality,Float,Shipped当前班生产信息-目标，实际，趋势，质量，缓冲，装运Paint to GA Buffer Count 油漆到总装的缓冲数第26页/共85页第二十六页，共86页。

27Performance Board 绩效绩效(jì xiào)板板The Performance board supports a specific group of operations or production area,usually one group leader’s area.绩效板支持一特定(tèdìng)工段的操作或生产区域，通常是工段长区域第27页/共85页第二十七页，共86页28Display 显示显示(xiǎnshì)Description 描述描述(miáo shù)Andon Downtime Clock暗灯停线时间(shíjiān)计时钟Equipment Downtime Clock设备停线时间计时钟Verification Station Downtime Clock质检工位停线时间计时钟Zone Downtime Clock区域停线时间计时钟Reset Buttons重置按钮Displays the total line downtime related to Andon calls显示与暗灯相关的总停线时间Display the total line downtime due to Equipment faults显示由于设备故障的总停线时间Displays the total line downtime due to quality calls and repairs in the verification stations显示由于质检工位的质量问题或返修而造成的停线时间Displays the total line downtime for each specific zone显示每个特定区域的总的停线时间Reset buttons are used to reset each downtime clock and pull count display after information is recorded.在记录数据后，用重置按钮重新设置每个停线计时钟和拉动次数第28页/共85页第二十八页，共86页。

29Final Process Board 终线流程终线流程(liúchéng)板板The Final Process Board supports the final process and production repair organizations by alerting them when help is needed.It also provides quality and throughput information.终线流程板支持最终工艺以及生产返修部门，提醒他们何时需要援助同时(tóngshí)提供了质量和产量信息第29页/共85页第二十九页，共86页30Quality OK Rates:质量通过率质量通过率Displayed is the Actual OK rates for the Quality Verification stations显示质检工位的实际通过率显示质检工位的实际通过率Throughput Performance 产量绩效产量绩效Displayed are Actual number of vehicles off EOL显示离开显示离开(lí kāi)终线的实际车辆数量终线的实际车辆数量On hold displays the number of vehicles On holdHold 表示滞留的车辆表示滞留的车辆OK-Status:Normal float level, all repair areas under the predetermined float levels.正常的浮动车辆标准，所有的返修区域在设定的浮动标准范围(fànwéi)内Level 1 Alarm, for Final Process only, System turns on level 1 alarm condition at a predetermined percentage of float level capacity.只对终线工艺而言，系统在预置的流动容量百分比上显示一级警示状态Level 2 Alarm:System turns on Level 2 Alarm condition at a predetermined percentage of float level capacity, prior to reaching maximum capacity.Group leaders involved in problem solving.二级警示：在达到最大容量之前，系统在预置的流动容量百分比上显示二级警示状态。

工段长参与问题解决Level 3 Alarm:System turns on at the maximum allowable float level capacity.Area manager and plant management involved in problem solving.三级警示：系统达到最大允许流动容量时的级别区域经理和生产基地领导班组参与问题解决 第30页/共85页第三十页，共86页31Maintenance Board 维修维修(wéixiū)板板The Maintenance Board supports the Maintenance organization by providing information related to abnormalities with equipment and tools and location where help is requested.提供设备异常的相关信息，支持维修部门并告知需要支援的地方The Maintenance Board displays will vary depending on the maintenance deployment strategy implemented.In some cases, extra marquees may be added as necessary to support the effectiveness of the maintenance function.Shown below are examples of departmental maintenance boards.依据实施的维修分布策略，维修板的显示有所不同。

有时，必须增加附加的车辆以支持维修的效率(xiào lǜ)以下是部门维修板的样例第31页/共85页第三十一页，共86页32Line 生产线生产线Condition 情况情况(qíngkuàng)Area or Conveyor Status区域(qūyù)或传动链状态Equipment Status设备(shèbèi)状态Equipment Uptime Actual设备实际工作时间Buffer Count 缓冲数Buffer Count 缓冲数Green-OK;Equipment and conveyors running.绿色-设备和流水线运行正常Red-Line not running.Conveyor or equipment not running红色-流水线或设备停止运行Green-OK 绿色-OKRed-Equipment fault 红色-设备故障Displayed is the Actual uptime of the equipment in each respective area.显示的是每个区域设备的实际工作时间Paint to GA buffer count 油漆到总装的缓冲数Trim 4 to Chassis 1 buffer count 内饰四到底盘一的缓冲数第32页/共85页第三十二页，共86页。

33Andon board Layout Planning 暗灯板规划暗灯板规划(guīhuà)布局布局When planning Andon board layouts and board configurations in a department, there are many things that need to be considered.Such as :当在一部门进行暗灯板的规划和版面设置时，需要考虑很多事如：What are the Team/Group sizes and locations? 班组/工段的大小和位置Can the group, including the verification station, be tied into one board?工段，包括质检工位，可否联成一块板？Is there a clear line of sight for team members? 班组成员是否能清楚看见What is the clearance height needed underneath the boards to allow for area activity?考虑区域活动的进行，板下的高度是多少？What is the maintenance deployment strategy for equipment faults?对于设备故障的维修(wéixiū)分布策略是怎样的？Are there central or satellite maintenance work shops? 是否有维修(wéixiū)中心车间？Are there scheduled controlled stops and starts? 是否有计划的控制停线和启动？Are procedures in place for routine reminders such as critical checks or material pull card pick-up?是否有程序作为日常行动的提醒，如关键检查或物料拉动卡的搜集？Is there flexibility in the system for future needs? 对于系统将来的需求是否有可塑性？Is there a nerve center or central meeting area? 是否有控制中心或会议区域？第33页/共85页第三十三页，共86页。

34Conveyor Line Layout 流水线的布局流水线的布局(bùjú)Key Points 关键点关键点Group Andon boards support Andon zones.Typically a zone represents one team(4-6 team members).A zone can be left or right operations and 2-5 workstations.One workstation equals the distance between the fixed position stop markings.In some cases due to isolated team locations, individual line segments, and automation, Andon boards may need to support the station and team level.工段的暗灯板支持暗灯区域通常一个区域表式一个班组工段的暗灯板支持暗灯区域通常一个区域表式一个班组(4-6个组员个组员)一个区域包含左边或右边的操。

一个区域包含左边或右边的操作，作，2-5个工位每个工位在固定停止位标记间的距离是相同的有些情况，由于独立的班组位置，单个工位每个工位在固定停止位标记间的距离是相同的有些情况，由于独立的班组位置，单独的分装线，暗灯板需要支持这个工位和班组独的分装线，暗灯板需要支持这个工位和班组Andon cords are installed in a clothesline fashion on moving lines or as call buttons in work cells and paint booths.Workstation lights are located at the end of the workstation.Run stop switches are located as required in the area.Speakers are placed in each zone.暗灯线在移动的生产线上的安装采用晒衣绳的样式，而在工作间和油漆房内采用按钮形式工位的末暗灯线在移动的生产线上的安装采用晒衣绳的样式，而在工作间和油漆房内采用按钮形式工位的末端设置端设置(shèzhì)亮灯。

运行停止开关在需要的区域放置每个区域都有扬声器运行停止开关在需要的区域放置每个区域都有扬声器第34页/共85页第三十四页，共86页35暗灯板位于生产线或区域(qūyù)的中央第35页/共85页第三十五页，共86页36System Operation 系统系统(xìtǒng)运行运行Information on the following pages describes the System help calls and Fault conditions of the Andon system.Described in detail are the corresponding visual and audio alerts for each type of help call and fault event listed below:以下几页的信息描述了暗灯系统的系统求助信号和故障状态对以下罗列的每一种求助信号和故障的目视和声音提示进行了详细的描述 Team Member help call 组员帮助需求 Electronic Error Proofing help call 电子防错帮助需求 Float Alarm 缓冲警报 Local Quality verification station help call 局部质量检验工位需求 Downstream quality verification station help call 后道工序质检(zhì jiǎn)工位需求 Critical check reminder 关键检查提示 Run stop 运行停止第36页/共85页第三十六页，共86页。

37Manipulator out-of-position and over-travel 操作者越位和超程Equipment and Conveyor Faults 设备(shèbèi)和传动链故障Entrance and Exit Conveyor Faults 传动链入口和出口故障Starved and Blocked 短缺和堵塞Status of Other Lines 其他线的状态Scheduled Start or Stop 计划启动或停线Production Status Information 生产状态信息Goal 目标 Sub-Assembly 分装线Actual 实际 Exit Conveyor Count 流出传动链车辆数Trend 趋势(qūshì) Bodies from Previous Process 前道工艺的车身Quality 质量 Float or Buffer 悬浮或缓冲车辆Downtime 停线时间 第37页/共85页第三十七页，共86页。

38Team Member activates an Andon call: 组员(zǔ yuán)激活暗灯需求： Andon board zone,station, or work cell number turns on flashing Yellow. 暗灯板上相关区域，工位或工作间的数字闪烁黄色 Unique zone audio signal is played 发出特定的区域声音信号 Yellow workstation light goes on solid 工位黄色灯不动 Fixed Position Stop is activated,except in work cells and Paint booths. 固定停止位发生作用，工作间和油漆房除外System Operation 系统系统(xìtǒng)运行运行第38页/共85页第三十八页，共86页39If Fixed Position Stop is reached before the Andon is reset:在暗灯重置之前到达了固定停止位： Conveyor stops and Downtime clock starts. 传动链停止，停线计时钟启动 Green Line Status Light (Trim 3)turns to flashing Red 生产线状态灯绿色变成红色闪烁 Flashing Yellow zone number remains on the Andon Board 暗灯板上依旧是闪动的黄色区域数字(shùzì) Unique Audio Signal for the zone plays fast mode. 独特的区域声音信号加快 Yellow workstation Light begins to flash 工位的黄色灯开始闪烁Second Pull or releasing the call button, resets the call event and the line resumes normal operation.暗灯线第二次拉动或释放按钮，流水线恢复正常运行 Conveyor restarts. 传动链重新启动 All lights return to normal operation. 所有灯回复正常状态第39页/共85页第三十九页，共86页。

40System Operation 系统系统(xìtǒng)运行运行When the error proofing OK signal is not received and the predefined Programmable Warning Point is reached, the error proofing system activates an Andon help call.当防错的OK信号没有被接收，而达到预先审定的可编程警告点时，防错系统激活(jī huó)暗灯求助需求 Andon board zone number turns on flashing Yellow 暗灯板上相关区域的数字闪烁黄色 Unique zone audio signal is played 发出特定的区域声音信号 Yellow workstation light turns on Sold 工位黄色灯不动第40页/共85页第四十页，共86页41If the Andon system doesn’t receive an OK, Release,or By-pass signal, the conveyor will stop at the fixed position stop when reached.如果暗灯系统没有接收OK、释放(shìfàng)或通过信号，当传动链到达固定停止位时就停线了。

Conveyor stops and Downtime clock starts. 传动链停止，停线计时钟启动 Green Line Status Light (Trim 3)turns to flashing Red 生产线状态灯(内饰三)绿色变成红色闪烁 Flashing Yellow zone number remains on the Andon Board 暗灯板上依旧是闪动的黄色区域数字 Unique Audio Signal for the zone plays fast mode. 独特的区域声音信号加快 Yellow workstation Light begins to flash 工位的黄色灯开始闪烁When the error proofing receives an OK,Release,or By-pass signal, the line resumes normal operation.当防错系统接收了OK，释放(shìfàng)或通过信号，生产线恢复正常运行 Conveyor restarts. 传动链重新启动 All lights return to normal operation. 所有灯回复正常状态第41页/共85页第四十一页，共86页。

42System Operation 系统系统(xìtǒng)运行运行OK status:Normal float level, all repair area under the predetermined float levels.OK状态：正常的流通车辆水平，所有的返修区域在设定的流通水平范围内 Final process Andon board float alarm stack light is Green. 终线工艺暗灯板流动警示灯是绿色的Level 1 Alarm, for Final Process only, System turns on level 1 alarm condition at a predetermined percentage of float level capacity.一级警示，只对终线工艺而言，系统在预置的流动容量(róngliàng)百分比上显示一级警示状态 Float alarm melody is played (on Final Process Board only) 发出流动警示音乐(只在终线板上) Final Process Andon Board Float Alarm Stack Light turns on solid Blue 终线工艺暗灯板流动警示灯变为常蓝色第42页/共85页第四十二页，共86页。

43Level 2 Alarm:System turns on Level 2 Alarm condition at a predetermined percentage of float level capacity, prior to reaching maximum capacity.二级警示：在达到最大容量之前，系统在预置的流动标准容量百分比上显示二级警示状态 Float Alarm “FA” turns on solid Yellow (all andon boards) 流动警示“FA”变为常黄色(所有的暗灯板) Float Alarm melody is played (all areas) 发出流动警示音乐(所有区域(qūyù)) Final Process Board Float Alarm Stack Light turns on solid Yellow. 终线工艺暗灯板流动警示灯变为常黄色Level 3 Alarm:System turns on at the maximum allowable float level capacity.三级警示：系统达到最大允许流动容量时的级别 Float Alarm “FA”turns on flashing Yellow 流动警示“FA”变为闪烁的黄色 Float Alarm melody is played (fast mode all areas) 发出流动警示音乐(所有区域(qūyù)节奏变快) Final Process board float alarm stack light turns on solid Red. 终线工艺暗灯板流动警示灯变为常红色第43页/共85页第四十三页，共86页。

44System Operation 系统系统(xìtǒng)运行运行Quality team member calls for help by pressing the appropriate quality zone button.质检人员按下相应的区域(qūyù)质量按钮寻求帮助 Quality zone number begins to flash Yellow. 质量的区域(qūyù)数字变为闪烁的黄色 Unique zone melody is played. 播放独特的区域(qūyù)音乐Team Leader responds to the quality verification station and presses the appropriate quality zone button to reset the event.班组长响应质量检验工位，再次按下相应的区域(qūyù)质量按钮 Quality zone number turns green 质量的区域(qūyù)数字变为绿色 Unique zone melody stops playing. 独特的区域(qūyù)音乐停止第44页/共85页第四十四页，共86页。

45System Operation 系统系统(xìtǒng)运行运行Quality team member calls for help by pressing the appropriate area quality button.质检人员按下相应的区域质量按钮寻求帮助 Verification station number is displayed flashing Yellow 表示质检工位的数字显示闪烁(shǎn shuò)的黄色 Quality/Float Alarm melody is played for 5 seconds 质量/流动警示音乐播放5秒种Group Leader responds to the call and the appropriate area quality button is pressed to reset the event.工段长响应，重新设置相关的区域质量按钮 Verification Station number is turned off and the display changes back to normal operation. 质检工位的数字变为正常的操作状态第45页/共85页第四十五页，共86页。

46System Operation 系统系统(xìtǒng)运行运行System automatically turns on Critical check lights 系统自动亮起关键检查灯 Critical check “C” turns on solid Yellow “C” 关键检查的C变为常黄色的C Critical check melody is played for 5 seconds 关键检查音乐播放5秒种 Critical check complete button turn on solid Blue for the appropriate zones 相关区域(qūyù)的关键检查完成按钮变为常蓝色第46页/共85页第四十六页，共86页47Team Leaders press their Critical check complete buttons once they have completed recording all their checks.The system will turn off the Critical Check Complete Button Lights as they are pushed.只要班组长记录了检查的数据，就按下关键检查完成按钮。

系统会关闭关键检查灯 Once all team leaders have pushed their Critical Check Complete buttons, the system will:一旦所有的班组长按下关键检查完成按钮，系统将 Turn the solid Yellow “C” back to green “C” 由常黄色(huángsè)的C变回绿色C If a Team Leader does not complete a Critical Check within the allowed time frame the system will:如果班组长在指定的时间范围内没有完成关键检查，系统将： Flash the Yellow “C” Critical Check Light. 闪烁黄色(huángsè)的关键检查灯 Play the Critical Check melody at Fast Mode for 5 seconds. 关键检查音乐加快播放五秒种 Flash the Critical Check Complete Button for the zones that did not complete their Critical Checks. 对于没有完成关键检查的区域关键检查完成按钮开始闪烁。

第47页/共85页第四十七页，共86页48System Operation 系统系统(xìtǒng)运行运行Team Member pulls the Red Run Stop rope or pushes a Run Stop button.Line stops immediately.组员拉动(lā dònɡ)红色运行停止线或按下运行停止按钮生产线立即停止 “RS” turns on flashing Red RS变为闪烁的红色 Pull cord or push button switch lights up Red 拉绳或按钮开关变红色 Specific Andon Zone light (2) turns on flashing Red 具体的暗灯区域灯(2)变为闪烁的红色 Green line status (Trim 1)turns flashing Red 绿色的生产线状态灯(内饰一)变为闪烁的红色 Unique zone melody plays fast mode until Run Stop is reset. 独特的区域音乐节奏变快直到重新设定运行停止开关 Downtime clock starts 停线时间计时钟启动第48页/共85页第四十八页，共86页。

49Team Leader or Member resets Run Stop 班组长或组员重新设定运行停止(tíngzhǐ)开关 Conveyor restarts 传动链重新启动 All lights return to normal operation 所有的灯回复正常操作状态.The Run stop should normally only be used when the conveyor line needs to stop immediately(emergency situations).In most cases the team member help call should be used which would stop the line at the fixed position stop and allow other team members to complete their standardized work.Some regions may refer to the Run Stop as an Emergency Stop.只有当流水线需要立即停止(tíngzhǐ)时才使用运行停止(tíngzhǐ)开关(紧急状态)。

大多数情况下，使用组员求助暗灯，流水线在固定停止(tíngzhǐ)位停线并可以使其他组员完成标准化操作有些区域把运行停止(tíngzhǐ)开关作为急停开关使用第49页/共85页第四十九页，共86页50System Operation 系统系统(xìtǒng)运行运行第50页/共85页第五十页，共86页51Limit switch activated and line continues to FPS 限制开关激活，流水线继续流动直到固定停止位 Specific Andon zone light turns on flashing Red 具体的暗灯区亮灯变为闪烁(shǎn shuò)的红色 Green line status(Trim 1)turns flashing Red. 绿色的生产线状态灯(内饰一)变为闪烁(shǎn shuò)的红色 Unique zone melody plays fast mode until over-travel reset switch is activated. 独特的区域音乐节奏变快直到超程开关重新激活 Downtime clock starts. 停线计时钟启动Manipulator placed back into position and resets over-travel condition操作者返回原位置，重新设定超程开关 Conveyor restarts 传动链重新启动 All lights return to normal operation 所有的灯回复正常操作状态.Key Point:Manipulator Over-Travel limit switch should be designated and located to stop the line at the FPS.关键点：操作者超程限制开关应设置在固定停止位，以停下生产线。

第51页/共85页第五十一页，共86页52System Operation 系统系统(xìtǒng)运行运行Equipment tied to the line is down 与生产线相联的设备停止运行 Specific Equipment cell light turns on flashing Red 具体(jùtǐ)的设备亮灯变为闪烁的红色 Green line status (Trim 1)turns flashing Red. 绿色的生产线状态灯(内饰一)变为闪烁的红色 Fault tone plays for the specified time. 在规定的时间内播放故障音调 Downtime clock starts. 停线计时钟启动第52页/共85页第五十二页，共86页53Conveyor Fault-Main Conveyor is Down: 传动链故障-主流水线停止： Conveyor(CON) cell light turns on flashing Red. 传动链亮灯(CON)变为闪烁的红色 Green line status (Trim 1)turns flashing Red. 绿色的生产线状态灯(内饰一)变为闪烁的红色 Fault tone plays for the specified time. 在规定的时间内播放故障音调 Downtime clock starts. 停线计时钟(shízhōng)启动System Operation 系统系统(xìtǒng)运行运行第53页/共85页第五十三页，共86页。

54System Operation 系统系统(xìtǒng)运行运行Entrance Conveyor Fault: 入口传动链故障 ENT cell light turns on flashing Red ENT亮灯变为闪烁(shǎn shuò)的红色 Green line status (Trim 1)turns flashing Red. 绿色的生产线状态灯(内饰一)变为闪烁(shǎn shuò)的红色 Fault tone plays for the specified time. 在规定的时间内播放故障音调第54页/共85页第五十四页，共86页55Exit Conveyor Fault: 出口传动链故障 EXT cell light turns on flashing Red EXT亮灯变为闪烁(shǎn shuò)的红色 Green line status (Trim 1)turns flashing Red. 绿色的生产线状态灯(内饰一)变为闪烁(shǎn shuò)的红色 Fault tone plays for the specified time. 在规定的时间内播放故障音调System Operation 系统系统(xìtǒng)运行运行第55页/共85页第五十五页，共86页。

56Conveyor Starved: 传动链拉空 STV cell light turns on flashing Red. STV亮灯变为闪烁(shǎn shuò)的红色 Green line status (Trim 1)turns flashing Red. 绿色的生产线状态灯(内饰一)变为闪烁(shǎn shuò)的红色 No melody is played. 没有音乐响起System Operation 系统系统(xìtǒng)运行运行第56页/共85页第五十六页，共86页57Conveyor Blocked: 传动链堵塞 BLK cell light turns on solid Red BLK亮灯变为不动的红色 Green line status (Trim 1)turns flashing Red. 绿色的生产线状态(zhuàngtài)灯(内饰一)变为闪烁的红色 No melody is played. 没有音乐响起System Operation 系统系统(xìtǒng)运行运行第57页/共85页第五十七页，共86页。

58Status of other areas or lines: 其他区域或生产线的状态 “--”Green changes to solid Red “T4” to show that Trim 4 is down. 绿色的“--”变为固定的红色“T4” ，表示内饰四停线了 When 2 or more lines or areas are stopped, the display will toggle between those statuses. 如果两个或更多生产线或区域停止，显示的信息将在这几个区域状态间转换 No melody is played. 没有(méi yǒu)音乐响起System Operation 系统系统(xìtǒng)运行运行第58页/共85页第五十八页，共86页59Scheduled Stop of the line: 生产线的计划停线： Goal number changes to a flashing “CS” 目标(mùbiāo)数字变为闪烁的CS Scheduled Start/Stop tone is played. 响起计划停线/启动的音调Scheduled Start of the line: 生产线的启动 Flashing “CS”changes to the Goal number. 闪烁的CS变为目标(mùbiāo)数字 Scheduled Start/Stop tone is played. 响起计划启动/停线的音调System Operation 系统系统(xìtǒng)运行运行第59页/共85页第五十九页，共86页。

60Production Status Information 生产状态信息生产状态信息The current shift’s Production Status Information is displayed on the lower portion of the Andon board.当前班的生产状态信息显示在暗灯板的下面部分当前班的生产状态信息显示在暗灯板的下面部分Each set of numbers is displayed separately and is updated automatically.每一组数字分别显示并自动更新每一组数字分别显示并自动更新Displayed numbers can change from green(OK) to red (NOT OK) to indicate the status to pre-programmed targets.The operation of the status information is described below:显示的数字从绿色变为红色表示状态未达到显示的数字从绿色变为红色表示状态未达到(dá dào)设定目标。

以下是描述状态信息设定目标以下是描述状态信息的运行情况的运行情况System Operation 系统系统(xìtǒng)运行运行Goal:Displays the current shifts scheduled number of units to be produced off the end of the line.The number is displayed in green.目标：显示当前班计划生产离开流水线末端的车辆(chēliàng)数量数字显示绿色Actual:Displays the current shift’s actual number of units produced off the end of the line.Displays green when the goal is met or going to be met and red if it is not met.实际：显示当前班生产的离开流水线末端的车辆(chēliàng)数绿色表示目标已达到或即将实现，红色表示目标没有达到第60页/共85页第六十页，共86页61Trend +/-:Continuously updated display indicating the current production performance (actual cars built)in relation to the schedule(goal)and remaining shift time.The trend value is calculated as follows:趋势趋势+/-：显示不断更新，表示与计划目标和剩余生产时间相关的当前生产运行状态：显示不断更新，表示与计划目标和剩余生产时间相关的当前生产运行状态(实际制造的车辆实际制造的车辆)。

用以下公式用以下公式计算趋势值：计算趋势值：The result is rounded to the nearest whole number.A positive value for the trend means production for that area is ahead of schedule and is displayed in green.A negative value means production is behind schedule and is displayed in red.Scheduled breaks,lunch and dinner times are not to be included in time values for the calculation.结果取整数趋势值是正数意味着区域生产超出计划，显示绿色负数结果取整数趋势值是正数意味着区域生产超出计划，显示绿色负数(fùshù)表示实际生产落后于计划，显示红色表示实际生产落后于计划，显示红色计划中的休息，用餐时间不包括在实际计算内计划中的休息，用餐时间不包括在实际计算内Example:Shift schedule or goal is 200 units and the shift ran for 90 minutes and built 45 units(Actual)before stopping for the 1st break.Normal shift hours minus breaks and lunch is 432 minutes.Below is the calculated Trend Value:样例：班次计划或目标是样例：班次计划或目标是200辆车，已运行辆车，已运行90分钟，在第一次休息之前已制造了分钟，在第一次休息之前已制造了45辆车。

正常的班次时间减去休息和辆车正常的班次时间减去休息和用餐是用餐是432分钟以下就是趋势值的计算：分钟以下就是趋势值的计算：(Goal 目标  Elapsed Shift Time 消耗生产时间) Shift Length 生产时间 第61页/共85页第六十一页，共86页62Production Status Information 生产状态信息生产状态信息Quality:The Quality value is continuously updated and indicates the line segment or area First Time quality measured at the Verification Station for the current shift.At the beginning of the shift this Quality number is blank.After a predetermined number of vehicles are inspected for the given area or line segment the Quality number is then displayed.As production continues, the Quality numbers are recalculated and updated continuously with the new Quality number.The Quality percent for the area or line segment is calculated as follows:质量：质量值是不断更新的，表示质检工位评估质量：质量值是不断更新的，表示质检工位评估(pínɡ ɡū)的当前班生产线一部分或区的当前班生产线一部分或区域的一次质量。

在班次启动时，此质量数值为空域的一次质量在班次启动时，此质量数值为空.在指定区域检验了规定数量的车辆后，在指定区域检验了规定数量的车辆后，质量值才显示随着生产的进行，质量数值重新计算不断更新区域的质量百分比计质量值才显示随着生产的进行，质量数值重新计算不断更新区域的质量百分比计算如下：算如下：System Operation 系统系统(xìtǒng)运行运行 Number Vehicles OK for Group 工段(gōngduàn)通过的车辆数 Total of Vehicle inspected at station 工位检验的总车辆数 第62页/共85页第六十二页，共86页63Downtime:The Downtime display indicates the accumulated downtime for the line segment or area for the current shift.It is the sum of equipment and conveyor faults, starved and blocked conditions, robot faults, operator delays(Andon)and any other downtimes(does not include time for breaks,lunches or dinners).The downtime value is rounded off to the nearest whole minute.停线时间：停线时间表示当前班部分(bù fen)生产线或区域累积的停线时间。

它是设备和传动链故障、拉空和堵塞、机器人故障、操作者延误(暗灯)以及其他停线时间的总和(不包括休息和用餐的时间)停线时间取接近的整数值S/A(Sub-Assembly Buffer Count):Displayed is the current buffer count of a sub-assembly or module being conveyed to the main process.This display is optional and is only displayed if the conveyor or buffer cannot be seen from the area.The value can be displayed in green or red to indicate an OK or not OK condition.分装线缓冲数：显示的是分装线或工作单元向主工艺流程传输的缓冲数此显示是可选择的，在传动链或缓冲看不见的情况下才显示显示的值为绿色或红色以表示OK或非OK状态Exit(Exit Buffer Count):Displayed is the current buffer count of the exit buffer.This is the supply buffer to the next process.This display is optional and is only displayed if the conveyor or buffer cannot be seen from the area.The value can be displayed in green or red to indicate an OK or not OK condition.流出缓冲数：显示的是当前流出的缓冲数，指流向下道工序的缓冲。

此显示是可选择的，在传动链或缓冲看不见的情况下才显示显示的值为绿色或红色以表示OK或非OK状态第63页/共85页第六十三页，共86页64How to use the Andon System 如何使用如何使用(shǐyòng)暗灯系统暗灯系统When there is a problem or out of standard situation, the team member pulls the Andon cord in his station to call for help.The zone melody is heard, and a light flashes on the board to alert the team leader and group leader that there is a problem in their zone that they need to support.当有问题或不符合标准的情况发生，组员拉动(lā dònɡ)暗灯寻求帮助区域音乐会响起，暗灯板上闪烁的灯提示班组长和工段长，在他们的区域发生了问题需要支持The team leader is responsible for responding to these Andon calls immediately to support the team member in repairing the problem.If the problem can be addressed within the station, the Andon is deactivated and the line continues on.When the problem cannot be resolved within the station, the team leader can either keep the line down at the fixed position stop if the problem interferes with the next process and continue the repair in station; they can reset the line and continue the repair if the problem does not affect the next processes in the zone; or they can tag the vehicle to be repaired further down the line.When the problem has been resolved,the question should then be asked, “How can we prevent this problem from happening again?” We have an opportunity to improve the process.班组长负责立即响应这些暗灯，支持组员修复问题。

如果问题可以在工位内解决，把暗灯复位，流水线继续移动如果问题不能在工位内解决，而这个问题会影响后道工艺流程，那么班组长在生产线到达固定停止位时停线继续返修；如果问题不影响后道工序，班组长保持流水线的移动并继续返修；此外班组长可以在车上贴标签以离线返修一个问题得到解决，应该自问一下“如何防止这个问题再次发生？”这就是改进工艺流程的机会第64页/共85页第六十四页，共86页65When the Andon should be activated: 何时拉动暗灯何时拉动暗灯 Safety problem 安全问题安全问题 Unable to complete job within cycle time 无法在周期时间内完成工作无法在周期时间内完成工作 Poor quality from previous processes来自前道工序较差的质量来自前道工序较差的质量 Material shortage or wrong parts 物料短缺或零件错误物料短缺或零件错误 Missing tools 遗失工具遗失工具 Malfunctioning equipment or tools 设备或工具失效设备或工具失效 Missing manifest,pull card,etc 装车单，看板卡没有装车单，看板卡没有 Bad or malfunctioning parts 零件的损坏零件的损坏(sǔnhuài)或失效或失效 Wrong sequence 排序错排序错 Unsure situations 不确定状态不确定状态Pulling the Andon should not be seen as a Negative but rather as an Opportunity to Continuously Improve the process.拉动暗灯不应该拉动暗灯不应该(yīnggāi)被否定，而是应看作是不断改进工艺的机会被否定，而是应看作是不断改进工艺的机会第65页/共85页第六十五页，共86页。

66How to use the Andon System 如何如何(rúhé)使用暗灯系统使用暗灯系统Step 1- Andon cord is pulled, station light goes on and a melody begins.步骤步骤1-拉暗灯，工位灯亮音乐响起拉暗灯，工位灯亮音乐响起When a team member finds a problem, they immediately communicate the situation to the team leader by pulling the cord.The light at his station goes on, the zone light flashes on the Andon board and a specific melody begins.A zone consists of three stations in this example.The team member of station 10 has a problem, so he pulled the cord.组员组员(zǔ yuán)发现问题时，通过拉暗灯立即向班组长汇报情况。

工位灯亮，而暗发现问题时，通过拉暗灯立即向班组长汇报情况工位灯亮，而暗灯板上的区域灯会闪烁，并响起特定的音乐在这副图例中一个区域包含三个工灯板上的区域灯会闪烁，并响起特定的音乐在这副图例中一个区域包含三个工位十号工位的组员位十号工位的组员(zǔ yuán)有问题，所以他拉动暗灯有问题，所以他拉动暗灯第66页/共85页第六十六页，共86页67Step2-Team Leader comes immediately and begins problem solving步骤步骤2-班组长立即赶到着手解决问题班组长立即赶到着手解决问题When the Team Leader hears the special zone melody and sees the yellow light, he knows that there is a problem from Zone 3, but he doesn’t know at first which station until he gets closer and sees the station light on.He immediately goes to the station to assist the Team Member.At this point problem solving begins.当班组长听到特定的区域音乐当班组长听到特定的区域音乐(yīnyuè)，看见黄灯亮，就知道区域，看见黄灯亮，就知道区域3有问题，但有问题，但还不知道是哪个工位直到走近看到工位的灯亮。

班组长立即赶赴该工位并协助还不知道是哪个工位直到走近看到工位的灯亮班组长立即赶赴该工位并协助组员开始解决问题组员开始解决问题How to use the Andon System 如何使用如何使用(shǐyòng)暗灯系统暗灯系统第67页/共85页第六十七页，共86页68Team Leaders must be trained on how to respond to Andon calls.Every problem has potentially a different solution.Proper response methods must be taught and coached on a daily basis.Andon Reaction plans are another method of training team leaders on proper Andon responses.班组长必须经过如何响应暗灯的培训每个问题有潜在的不同解决方案班组长必须学会合理的响应方式并每天接收指导暗灯行动计划是另一种培训班组长合理响应暗灯的方法If the problem is solved immediately, the andon is reset by pulling the cord a second time, and the line continues.If the problem solving involved an improvement to the process, it must be standardized.如果问题迅速(xùn sù)解决，再拉一次暗灯线使生产线继续流动。

如果问题的解决包含了对工艺的改进，就必须标准化第68页/共85页第六十八页，共86页69Step 3-Line continues to move to Fixed Position Stop步骤步骤3-生产线继续生产线继续(jìxù)流动到固定停止位流动到固定停止位The Team Leader makes every effort to fix/solve the problem before the job reaches FPS.If the problem is not solved immediately, the line continues to move until the vehicle reaches the next FPS.Then the line stops or the Team Leader makes a decision to continue the repair into the next station and releases the Andon.班组长尽力在到达固定停止位之前修复班组长尽力在到达固定停止位之前修复/解决问题如果问题没有马上解决，生解决问题。

如果问题没有马上解决，生产线在车辆到达下一个固定停止位之前继续产线在车辆到达下一个固定停止位之前继续(jìxù)流动，那么班组长决定是停线流动，那么班组长决定是停线还是到下个工位去返修同时释放暗灯还是到下个工位去返修同时释放暗灯How to use the Andon System 如何使用如何使用(shǐyòng)暗灯系统暗灯系统 第69页/共85页第六十九页，共86页70The FPS locations or Foot Prints are the length of one vehicle plus the gap between it and the next unit.It is also the distance between the same points of two vehicle(e.g from the front of axle of car “A” to the front of axle of car “B”).固定停止位的设置是车辆的长度和它与下一辆车的间距之和它也是两辆车相同位置点的距离(如，从A车的前轴到B车的前轴)When the line stops for any reason,(e.g for breaks, shift ends, andon stops)it will continue until the vehicle reaches the FPS.The reason for this, is so that the Standardized Work of Team Members is not interrupted.The only time the line will stop immediately is when the Run Stop is activated.如果由于某些原因要停线(休息，下班，暗灯停线)，流水线只有在车辆到达固定停止位时才停下来。

这是为了组员的标准化操作不会(bù huì)被打乱只有在激活运行停止开关时生产线才会马上停止第70页/共85页第七十页，共86页71Step 4 - When vehicle reaches the FPS,line stops and the line name on the board flashes red.步骤步骤4- 当车辆到达固定停止位时，生产线停止，暗灯板上的流水线名称闪烁红色当车辆到达固定停止位时，生产线停止，暗灯板上的流水线名称闪烁红色If the Problem is not solved before the vehicle reaches the FPS, the line stops, and the zone light on the main Andon board continues to flash yellow.The line name (Trim 3)begins to flash red.如果问题如果问题(wèntí)在车辆到达固定停止位之前没有解决，流水线停止，暗灯板上的区在车辆到达固定停止位之前没有解决，流水线停止，暗灯板上的区域灯继续闪动黄色，流水线名称域灯继续闪动黄色，流水线名称(内饰三内饰三)闪动红色。

闪动红色How to use the Andon System 如何如何(rúhé)使用暗灯系统使用暗灯系统第71页/共85页第七十一页，共86页72At the same time, a timer begins which tracks the downtime for the area.This information is used by leaders for analysis purposes.Tracking downtime by area allows us to see possible problem areas.This helps us analyze line balancing, or cycle problems, and helps us measure out plant capacity.同时，对该区域的停线时间计时这个(zhè ge)信息是为领导分析所用追踪区域的停线时间使我们能发现可能存在问题的区域这有助于我们分析线平衡以及重复的问题，并测量出生产基地的产能第72页/共85页第七十二页，共86页73Step 5-Problem is addressed, and Andon cord is pulled to restart the line.步骤步骤5-解决了问题，拉动暗灯线重新启动生产线解决了问题，拉动暗灯线重新启动生产线When the problem solving is successful and the repair completed within the station, or the repair is continued in the next station, or a temporary countermeasure is put in place, the cord is pulled again.The Andon board returns to green, indicating the line is OK.The melody stops and the line starts moving again.如果成功解决问题并在工位内完成返修，或是在下个工位继续返修，采取临如果成功解决问题并在工位内完成返修，或是在下个工位继续返修，采取临时对策，就再次拉动暗灯线。

暗灯板变回绿色，表示生产线时对策，就再次拉动暗灯线暗灯板变回绿色，表示生产线OK音乐停止音乐停止(tíngzhǐ)，流水线重新移动流水线重新移动How to use the Andon System 如何如何(rúhé)使用暗灯系统使用暗灯系统第73页/共85页第七十三页，共86页74How to use the Andon System for Continuous Improvement 为了不断改进如何为了不断改进如何(rúhé)使用暗灯系统使用暗灯系统Andon is a key enabler to help us to continuously improve our process.暗灯是帮助我们不断改进工艺的关键驱动因素Andon downtime tracking and recording should be used by leaders to analyze problem areas and identify waste in the current process.领导追踪并记录暗灯的停线时间以分析问题区域，并识别现有工艺流程中的浪费The focus should be on the pulls with the highest frequencies, not the pulls with the highest downtime.High downtime pulls will be easily recognized because of the downtime.Andon pulls with a high frequency rate means that the root cause of the problem has not been addressed.Also frequent Andon pulls absorb a lot of the team leaders time and effort, and should therefore be identified as waste generators.应关注拉动次数最多的暗灯，而不是最长停线时间的暗灯拉动。

长时间停线的暗灯拉动很容易确认而高频次的拉动暗灯表示问题的根本原因还没有解决同时，经常的拉动花费了班组长大量的时间和精力(jīnglì)，被视为浪费的产生Downtime data should be analyzed after a predetermined period of time (weekly,bi-weekly, monthly).After analyzing downtime data and recognizing problem areas, leaders need to start the problem solving process.在规定的一段时期后分析停线数据(每周，每两周，每月)在分析停线时间和确认问题区域后，领导需要启动问题解决流程During the problem solving we need to recognize the root cause of the problem, define and implement countermeasures to tackle the root cause, and then implement a follow-up process to make sure the root cause has been eliminated.在问题解决的过程中，我们需要确认问题的根本原因，定义并实施解决根本原因的对策，并实施跟踪流程确保消除根本原因。

When the root cause has been found and eliminated, this type of andon pull should not occur anymore.当发现并消除了根本原因，此类暗灯的拉动就不会再发生第74页/共85页第七十四页，共86页75Roles and Responsibilities 角色角色(jué sè)和责任和责任Role of the Team Member 组员的角色组员的角色Follow Standardized Work 执行标准化操作执行标准化操作Actively watch for out-of-standard situations.积极注意非标准状况积极注意非标准状况If an abnormality or defect is discovered that cannot be immediately corrected, pull the Andon cord, and continue with the rest of the cycle until support arrives.如果发现异常状况或缺陷，但不能马上纠正，如果发现异常状况或缺陷，但不能马上纠正，就拉动暗灯，继续剩余就拉动暗灯，继续剩余(shèngyú)的操作直到的操作直到支持人员的到来。

支持人员的到来Support team leader with problem solving and repair as required.支持班组长解决问题并进行必要的修复支持班组长解决问题并进行必要的修复 第75页/共85页第七十五页，共86页76Role of Team Leader 班组长的角色班组长的角色Hears the andon melody and looks at the andon board for more information.听到暗灯音乐，观察暗灯板得到更多信息听到暗灯音乐，观察暗灯板得到更多信息Goes immediately to the area of the andon call to investigate and support.立即赶赴暗灯拉动的区域支持立即赶赴暗灯拉动的区域支持Hears a description of the problem and takes responsibility for the problem.听取问题的描述并对此问题负责听取问题的描述并对此问题负责Begins immediate correction of the problem.立即开始纠正问题立即开始纠正问题Resets the andon system by pulling the cord when he has determined a correction can be make.Begins problem solving with the support of the team member.如果如果(rúguǒ)确定能进行修复，重新设置暗灯系统。

在确定能进行修复，重新设置暗灯系统在组员的支持下解决问题组员的支持下解决问题Calls the group leader for support if the problem cannot be solved quickly.如果如果(rúguǒ)问题不能马上解决，通知工段长问题不能马上解决，通知工段长第76页/共85页第七十六页，共86页77Role of Group Leader 工段长的角色工段长的角色Support the Team Leader if he is not able to correct the problem, and get the line running as soon as possible.如果班组长不能纠正问题，给予支持，尽量如果班组长不能纠正问题，给予支持，尽量保持生产线运行保持生产线运行Call for additional support as needed (e.g maintenance, quality, manufacturing engineering, etc)寻求必要的其他支持寻求必要的其他支持(维修，质量，制造工程维修，质量，制造工程(gōngchéng)部门，等部门，等)Work with the Team Leader to make sure the root cause is identified and countermeasures implemented.和班组长一起确认根本原因并执行对策和班组长一起确认根本原因并执行对策Monitor downtime,identify problem areas and work with all available resources to eliminate problems.监控停线时间，识别问题区域，与所有现有监控停线时间，识别问题区域，与所有现有的支持人员合作消除问题。

的支持人员合作消除问题第77页/共85页第七十七页，共86页78Role of Maintenance Team Member 维修人员的角色维修人员的角色Hears the Maintenance Andon fault tone or melody and looks at the Andon board for more information.听到维修暗灯的故障声调或音乐，观察暗灯听到维修暗灯的故障声调或音乐，观察暗灯板获得更多信息板获得更多信息Goes immediately to the area of Andon Fault.立即赶赴发生故障的区域立即赶赴发生故障的区域Investigates the problem and begins immediate correction of the problem.检查问题检查问题(wèntí)，立即纠正，立即纠正Calls Group Leader for support if the problem cannot be solved quickly.如果问题如果问题(wèntí)不能马上解决，通知工段长不能马上解决，通知工段长。

第78页/共85页第七十八页，共86页79Role of the Quality team member at the Verification Station检验工位质量人员的角色检验工位质量人员的角色Follow Standardized Work 执行标准化执行标准化操作操作If an abnormality or defect is discovered, push the corresponding Production Team Zone button, and record the defect information.如果发现异常或缺陷，按下相关生产班如果发现异常或缺陷，按下相关生产班组区域组区域(qūyù)的按钮，并记录缺陷的按钮，并记录缺陷Support the Team Leader with problem solving as required.如果需要，支持班组长解决问题如果需要，支持班组长解决问题Follow the ‘Alarm Escalation Process’ to notify the appropriate levels of management for repetitive defect occurrences.遵循遵循“警告上报流程警告上报流程”，对于重复发生的，对于重复发生的缺陷通知相应的管理层。

缺陷通知相应的管理层 第79页/共85页第七十九页，共86页80Support for Andon 暗灯的支持暗灯的支持(zhīchí)The diagram shows the span of support within the organization.The significance of the inverted triangle is that the Team Member is at the top, supported by the entire organization underneath.When the Team Member needs help, he pulls the Andon cord, and support comes from the Team Leader.For complicated problems, the Team Leader calls for support from the Group Leader, and so on down the span of support.图例表示了整个机构支持的延伸范围倒三角的含义是组员在最上层，整个在下面的机构对其支持。

组员需要支持时，拉暗灯，直接的支持来自班组长对于(duìyú)复杂问题，班组长寻求工段长的支持，以此往下延伸第80页/共85页第八十页，共86页81Roles and Responsibilities 角色角色(jué sè)和责任和责任第81页/共85页第八十一页，共86页82Summary 总结总结(zǒngjié)Andon is a key enabler to help us to ‘Build Quality In-Station’.暗灯是帮助我们“制造工位质量”的关键驱动因素Andon is a tool used by the Team Member to ‘Call for Help’ when an out of standard condition occurs.It is a communication system that provides ‘Status At A Glance’.当出现非标准情况，组员把暗灯作为一种工具使用以“寻求帮助”它是一个交流信息的系统，对于状态一目了然Andon immediately begins the problem solving process.暗灯可以立即启动问题解决流程Andon is a tool that helps us to continually improve our operations.暗灯是帮助我们不断改进操作的一种工具。

The Andon system is applied in a common fashion, however, certain aspects are tailored to meet the specific environment and process requirements of a particular shop.暗灯系统的应用很普遍，然而，在一特殊车间为满足特定的环境和工艺需求，一些方面进行了相应(xiāngyīng)的调整Organization must be properly trained and understand their roles and responsibilities.整个机构人员要经过适当的培训，理解他们的角色和责任Andon operational success relies on the GM-GMS elements being in place and working together.暗灯运行的成功取决于GMS各要素间互相的作用第82页/共85页第八十二页，共86页83Appendix:References 附录附录(fùlù)：参考文献：参考文献第83页/共85页第八十三页，共86页。

84Appendix:Revision Log 附录附录(fùlù)：审核日志：审核日志第84页/共85页第八十四页，共86页85感谢您的观看(guānkàn)！第85页/共85页第八十五页，共86页内容(nèiróng)总结1缓冲警示：黄灯常亮 2级警示，黄灯闪烁3级警示通常一个区域表式一个班组(4-6个组员)显示的值为绿色(lǜ sè)或红色以表示OK或非OK状态感谢您的观看第八十六页，共86页。