# Industry 4.0 Roadmap: Implementation for Small and Medium-sized Enterprises
## 3 Results
### Andon System--The IoT Applied to Quality Control  
Quality is the main driver of an exceptional production plant. Non-conformances must be kept under control in order to provide customers with the best quality and to maintain favorable productivity.  
Real-time visibility and immediate intervention regarding waste are necessary to manage non-conformances. Furthermore, tracking trends in performance over time is also crucial to improve the efficiency of the operations in the assembly line.  
Andon is a term that refers to a system that notifies users of a quality or processing problem. An Andon system is one of the elements described in the Jidoka quality control method pioneered by Toyota as part of the Toyota Production System and belongs to the lean production approach [48].  
The Andon system proposed within this paper uses a TL70 Modular Tower Light with a wireless radio base connected to a DXM700 Wireless Controller. The data are pushed to the Banner Cloud Data Services (CDS) to create a dashboard and perform Cloud Computing activities.  
The Andon system uses two of the technologies selected in Section 2.1.2: the IoT and Cloud Computing. Implementation following the roadmap is described in Table 3.  
\begin{table}
\begin{tabular}{c c c} \hline
**Step Number** & **Step Description** & **Application for This Solution** \\ \hline
0 & Identify bottlenecks & The number of quality non-conformances has been increasing for a long time. Quality failures shall be detected immediately, and countermeasures shall be applied as soon as possible. \\ \hline
1 & Develop a strategy & Every work cell in the assembly line will get a traffic light that is manually switched to notify users of quality non-conformances. It will generate real-time data and will allow employees to resolve the issues in a short period of time. \\ \hline
2 & Ideas and Prototypes & “Think big but start small”: A model work cell was created in which the first prototype was tested. \\ \hline
3 & Connect/plug-in your devices & A traffic light was installed and connected to the controller, the dashboard was set and the Andon team was ready to analyze the data. Some dry runs were performed until the system ran stably. \\ \hline
4 & Analyze & Andon team created daily KPIs to control the evolution of quality non-conformances and analyze the results, asking the question “Am I winning or am I losing?”. \\ \hline
5 & Go live & Once the results were verified and the Andon system proved that the IoT could help to track and reduce quality non-conformances, the Andon system went live and was ready to be extended to other work cells. \\ \hline \end{tabular}
\end{table}
Table 3: Andon system—roadmap application.  
Total investment for the Andon system was $1194 (implementing a single Tower Light), but this is easily extendable by acquiring new Tower Lights (each $315) [49]:  
* TL70 Modular Tower Light ($315);
* DXM700 Wireless Controller ($579);
* Banner Cloud Data Services (CDS)--Starter ($300--Annually).  
Quantitative Results  
The Andon system was installed in January 2020 in the Munich manufacturing site of a biomedical company, as shown in Figure 7. The success of the solution was evaluated using two KPIs for six months, as shown in Table 4.  
* The number of non-conformances measures the amount of non-conformances created in the production line and incoming inspection areas during a month. The number of non-conformances decreased by 63% since the introduction of the Andon system.
* The processing of non-conformance takes on average 10 working hours (root-cause analysis, definition of countermeasures, implementation of countermeasures, etc.). Savings are measured in working hours based on the jumping-off point (JOP), which was February 2020.