KARES ANDON is the digital Andon platform for the modern factory floor. A stopped station loses money from the first second — but on most floors the alarm is still a shout, a walk, or a light nobody is watching. KARES ANDON turns every fault into a routed, timed, accountable event. Deployed in weeks on tablets and phones — no PLC required to start.
Normal operation. The station produces; the board stays calm.
An engineer accepted the alert. The operator sees "Help is on the way" with a live timer.
Critical and unacknowledged. Escalation timers are running; the hot list shows it first.
How downtime is handled today — and the KARES ANDON way.
The operator interface is built for speed and durability; the responder workflow for accountability.
Oversized touch targets, high contrast, zero typing to raise an alert. The operator picks a category: Material · Fault · Quality · Safety — about 2 seconds.
Every alert is written to the tablet's encrypted local queue before anything touches the network. If Wi-Fi drops the alert is queued, not lost — and syncs 100%, in order, no duplicates.
Notifications go to the right team — maintenance, electrical, quality — not the nearest body. Priority sound + vibration profiles are tested against >85 dB ambient noise.
The first engineer to tap Accept wins the job — exactly one owner per ticket, enforced by server-side transactions. No duplicated trips, no orphan jobs.
The 60-second and 5-minute rules fire automatically and are logged — silence can no longer bury a breakdown. Nobody gets forgotten.
Factory-wide GREEN / YELLOW / RED status on an overhead TV, readable from 30 ft. It carries no personal data — a sanitized status feed only.
Closing a ticket requires the root cause and the action taken. Trustworthy analytics from the first week, clean data for your CMMS.
Every ticket feeds MTTR, root-cause frequency, downtime trends and engineer response metrics — daily/weekly dashboards with CSV export.
Deny-by-default rules, an append-only audit trail, TLS/WSS everywhere. The security rules ship with a 20+ assertion test suite that runs in CI before every deploy.
The operator at the station, the engineer on the move and the supervisor at the board — each with an interface optimized for exactly their job, all synchronized in real time.
Behind the three screens runs a fourth persona. Every ticket automatically feeds MTTR, mean-time-to-resolve, root-cause frequency, downtime trends and engineer response metrics — with daily/weekly dashboards and CSV export for compliance and CMMS.
The whole loop — from fault to structured report — typically completes inside five minutes.
The operator taps a category. Saved locally, sent to the cloud, the station turns YELLOW.
~2 secondsThe ticket is created; the push lands on the responsible team's phones with machine + location.
~1 secondThe first engineer claims it; the escalation timer stops; the operator sees the name.
goal <60 sGuided report: root cause, action, downtime, prevention. The board returns to GREEN.
3–5 minutesStage 1 runs on standard Android/iOS tablets and phones — no PLC wiring, no proprietary buttons, no electricians. Mount a tablet at the station, log in, and the line is covered the same day. Launch criterion: zero data loss during network outages — tested, not promised.
Silence can't bury a breakdown: the rules fire on their own and every step is logged.
The ticket opens RED and is routed to the responsible team. Escalation timers start running.
An unacknowledged alert escalates to the shift supervisor's phone — and it's logged.
Still unresolved? The engineering manager is notified automatically. The issue can no longer go invisible.
Token-derived identity, rules closed to cross-user reads. The board receives a zero-PII status feed; it can't write.
Every alert, acceptance, escalation and resolution is recorded immutably. Forged audit events and client writes are provably rejected.
The security rules ship with an automated 20+ assertion test suite that runs before every deploy. Transport is TLS/WSS everywhere; data handling follows GDPR principles: minimization, retention policy, access logging.
From a 10-machine workshop to a multi-building plant — any facility where a stopped station costs money and the response today is a shout or a phone call.
Takt-time lines where a minute of stoppage ripples through the whole shift.
Filling and packaging lines with strict hygiene windows and perishable batches.
High-speed converting machines where jams are frequent and response speed is everything.
Multi-floor mills where finding the right mechanic still means walking.
CNC parks where one down spindle silently kills the day's schedule.
SMT and assembly cells with quality holds that need instant routing.
Stage 1 is a six-week deployment; every later stage builds on the same platform without disruption. The road to Industry 4.0 is an upgrade, not a migration.
Three UIs, manual triggers, escalation, audit trail, MTTR analytics, admin panel — deployed on your tablets and phones.
An industrial gateway polls the PLCs (Modbus / OPC-UA); machine faults raise tickets automatically — no operator tap needed.
A dedicated analytics database for long-horizon trends, OEE deep-dives and predictive-maintenance queries.
Location-aware engineer routing, live parts inventory and barcode-scanned consumption on the resolution screen.
Start with a single line: we deploy the operator tablet, engineer app and Andon board on a pilot area, configure your machines and escalation rules, and measure MTTR together from week one.