Andon Software for Real-Time Problem Resolution

MileSoft Andon is a shop-floor alert and response platform built on the lean-manufacturing principle that the fastest way to reduce downtime is to collapse the time between a problem occurring and the right person responding. Operators flag quality, material, or machine issues via call buttons; machines trigger automatic alerts via PLC fault signals or cycle-time deviation; sensors trigger alerts on out-of-spec readings. Every event routes instantly through an escalation workflow — supervisor, maintenance, quality, material handling — until it's resolved.

The platform accepts signals from PLCs (Siemens, Allen-Bradley, Mitsubishi), machine I/O, and MES systems alongside operator call buttons, so a single Andon event stream represents every relevant disruption on the line. Large overhead LED displays, line-side monitors, supervisor desktop dashboards, and mobile app notifications all share the same real-time event stream. Typical rollouts see a 60–80% reduction in mean-time-to-respond once Andon is in place and integrated with the factory's response organization.

The real ROI shows up after the first few weeks of data. Every event is logged with reason code, line, station, shift, and resolution time — so dashboards expose the recurring issues that cause chronic downtime and quietly erode OEE. MTTR trends, top downtime causes by shift and station, and OEE movement all become queryable, feeding SPC and lean improvement programs. Andon integrates with MES and ERP, supports barcode and RFID handshakes, and scales from single-line pilots to multi-plant deployments. For manufacturers serious about OEE, Andon is the single highest-ROI Industry 4.0 investment available.