Operator Dashboard & Andon Template

Purpose

This template is designed to give operators concise, actionable real-time information so they can make correct immediate decisions and escalate effectively when help is needed. Keep displays focused on what an operator can act on in the next 5–15 minutes.

Layout & Priority Rules

1. Single glance zone (top-left): current OEE vs target and trend sparkline — clearly visible from the line.
2. Active issues zone (top-right): active downtime events and quality holds with owners and elapsed time.
3. Immediate actions zone (center): next actions for the operator (what to do now), prioritized and time-boxed.
4. Plan & progress zone (bottom-left): today's production plan, target vs actual pieces, and short ETA for next batch.
5. Notes & Andon controls (bottom-right): operator notes entry, Andon call buttons, and visible escalation contacts.

Use high-contrast color only for status (green/yellow/red). Avoid decorative graphics. Limit the number of widgets to what fits without scrolling.

Widgets & Fields (recommended)

• OEE Snapshot: current OEE %, target OEE %, last-hour trend sparkline, rolling 24h average. Tooltip shows breakdown (Availability, Performance, Quality).
• Active Downtime Events: event ID, short cause code, start time, elapsed minutes, owner (role and name), suggested next action. Click to expand notes/history.
• Quality Holds: part number, defect summary, quantity held, holding inspector, immediate containment step (e.g., stop line, segregate parts).
• Today's Plan: current order, target quantity, completed quantity, percent complete, and next changeover ETA.
• Next Actions: 1–3 prioritized tasks the operator should complete now (with checkable action buttons or acknowledgment).
• Operator Notes: short free-text field to capture observations (timestamps auto-attached). Keep entries brief—these feed handover and problem logs.
• Andon Controls: soft-touch buttons for tier-1, tier-2, and emergency calls. Each button shows expected response time and escalation contact if unanswered.

Visual & Interaction Rules

• Use a consistent color code: Green = on-target, Amber = attention required, Red = stop/urgent.
• Show elapsed time for events in minutes; highlight when thresholds are crossed (e.g., 5, 15, 30 minutes).
• Keep text short and action-focused. Use icons only if universally understood on your shop floor.
• Provide a single place to acknowledge an Andon call and record the immediate action taken.

Andon Rules & Escalation Flow (template)

1. Operator presses Tier-1 Andon for help from team lead. Team lead expected response: 5 minutes.
2. If no response or issue unresolved after 10 minutes, auto-escalate to Tier-2 (supervisor) with the event summary and elapsed time.
3. If safety or critical quality risk is indicated, press Emergency Andon which notifies safety/quality manager and stops affected lines (defined per process).
4. Every escalation includes: event ID, short reason, operator note, current OEE impact, and required containment action.
5. All Andon events are logged with timestamps and owner acknowledgments for later review.

Example Thresholds & Acceptance Criteria

Sample thresholds to start with — adapt to your process:

• Downtime auto-flag: > 2 minutes (amber) · escalation: > 10 minutes (red)
• Quality hold: any suspect part > 1 piece triggers hold + immediate notification
• OEE deviation: > 10% below target triggers review prompt

Acceptance criteria: operator can determine required action within 15 seconds; Andon calls register and escalate reliably; dashboard reduces unnecessary escalations while ensuring critical events get attention.

Implementation Notes

• Data sources: MES for production plan and counts, CMMS or OEE system for events, QC system for holds, and a simple operator input feed for notes/acknowledgements.
• Refresh cadence: 10–30 seconds for active events and OEE; operator notes and acknowledgments should be near real-time.
• Form factor: large wall displays for shared visibility, small operator terminals for interaction. Keep the same core layout across sizes by hiding nonessential widgets on small screens.
• Localization: use local language and shop-floor terminology for cause codes and roles.

How to Avoid Noisy Dashboards

• Limit alerts: only escalate when an event crosses a meaningful threshold.
• Prioritize visible items: show only active issues and the most actionable information.
• Use clear owners: every event should show a responsible role or person to prevent confusion.
• Measure dashboard effectiveness: track acknowledgment times, unnecessary escalations, and operator feedback for 30 days after deployment.

Quick Example Escalation Matrix (editable)

Tier-1: Line Lead (response 5 min) · Tier-2: Supervisor (response 10 min) · Tier-3: Maintenance/Quality Manager (response 20 min) · Emergency: Safety/Plant Manager (immediate)

Next Steps & Customization

Start with this template on one line as a pilot. Collect operator feedback, measure acknowledgment and escalation patterns, then adjust thresholds and displayed fields. Keep the operator experience simple; iterate based on usage data and frontline input.