The Phoenix Project: A Novel About IT, DevOps, and Helping Your Business Win
by Gene Kim, George Spafford, and Kevin Behr talks about something called the Andon Cord!
Though introduced as a innovative device, it has now become an industry standard!
An Andon cord is a system in manufacturing, particularly associated with the Toyota Production System, that allows any worker to pull a cord or press a button to immediately signal a problem on the production line.
Pulling the cord triggers a visual or audible alert, such as a flashing light or siren, to notify supervisors and other workers to stop the line or address the issue to prevent defects from progressing.
The system is a key part of the principle of Jidoka, or “automation with a human touch,” which empowers employees to take ownership of quality control and continuous improvement.
The idea is actually in its extreme simplicity! A worker pulls the cord or presses a button when they encounter a quality issue, defect, safety problem, or other abnormality.
The line may be stopped, or the problematic section halted, to prevent the production of more defects.
The next step is for a team leader or supervisor who comes to the worker’s station to help identify and resolve the root cause of the issue.
The chief aim here is that this system empowers all workers to be proactive in maintaining quality and efficiency, rather than waiting for a supervisor to find a problem.
Though this may lead to waste in time and stall in the production; in the long run it has been found that it leads to more defect detection and greater production value which of course raises the brand value and the only thing the bosses worry about; PROFIT!
The modern adaptations now replaces the traditional cord with buttons, switches, or other digital interfaces to improve safety and workplace tidiness.
The system has also been adapted for use in other fields, such as software development, using digital tools to manage defects.
The core principle of using automated systems to detect and signal problems is also seen in advanced systems like Netflix’s “Chaos Monkey,” which intentionally breaks parts of their own systems to find vulnerabilities and correct them at the primary or root level!
Of course not many vulnerabilities can you find in a SS Rajamouli movie!
Now give rest to another cord! Vocal this time and sleep!
Shubh ratri!
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