In 30 seconds
- From Toyota: any worker can pull a cord to stop production.
- Problems are fixed at the source before they multiply.
- In software: a broken build stops new work until it's green.
Origins
In the Toyota Production System, an andon cord or button lets any worker signal a problem. A light shows where the issue is, a leader responds, and if it can't be fixed quickly, the line stops. Stopping early is cheaper than shipping defects.
In software
- A failing build on the main branch: everyone stops and helps fix it
- A production incident: new work pauses until it's understood
- A blocked card on the board: flagged loudly so others help
Making it work
Andon only works when raising a problem is safe and rewarded. If people are blamed for pulling the cord, they stop pulling it. Pair it with working agreements about who responds and how fast.
Myth vs reality
Myth · Stopping the line wastes time.
Reality · It prevents much larger waste later.
Myth · Only leaders can stop work.
Reality · Andon lets anyone raise the signal.
Myth · Andon is a dashboard light.
Reality · The response behind the light is what matters.
FAQ
What's an andon cord?
The physical cord in Toyota plants; the name is used for any stop signal.
How does andon relate to jidoka?
Jidoka is building in the ability to stop on abnormality; andon is the signal.
Do we need special tools?
No; a CI alert and a team rule are enough to start.