Andon Line Stop Escalation Software
An andon pull starts a clock. Kissflow routes that stop through tiered, timed escalation, tracks who responded and how fast, and codes the downtime reason before the line restarts, so every stop feeds MTTR and OEE reporting instead of a shift-end guess.
Trusted by energy operators worldwide
One escalation path from the andon pull to the line restart
The andon light comes on at station 14. In plants that run well, someone is already moving before the buzzer finishes; in most plants, the operator is still waiting to find out who is coming.
Today an andon pull triggers a light, maybe a buzzer, and word travels by radio or a walk down the aisle. If the team lead does not respond inside the target window, nothing pushes the call up the chain automatically, and the line sits stopped while someone tracks down whoever is free. By the time the stop closes, no one can say for certain how long it actually ran or why.
Kissflow gives every andon event a tracked lifecycle: capture the pull with station and line, escalate automatically by tier on a fixed response clock, log who responded and what fixed it, code the downtime reason, and roll every stop into MTTR and OEE reporting without a shift-end spreadsheet.
Every line-stop event that isn't tracked is a downtime cause nobody can explain later
Andon calls travel by radio, not by record
A pull triggers a light and maybe a shout down the aisle, with no timestamp and no trace of who was notified.
Escalation depends on someone remembering to escalate
If the team lead does not respond, there is no automatic timer pushing the call to a supervisor. The line just stays down.
Downtime reason gets guessed at shift end
By the time anyone logs why the line stopped, the detail is gone and the reason code is a best guess.
MTTR and OEE numbers arrive too late to act on
Response and repair time roll up days later in a report, long after the pattern behind three stops in one shift could have been caught.
Six modules. Built for how andon actually escalates.
Every module ships with default forms, escalation logic, integrations, and dashboards. Configure each one to your response policy in the visual builder.
Andon event capture
Captures the line-stop pull with station, line, and timestamp the moment it happens, whether triggered from a pull cord, HMI button, or mobile app.
Tiered escalation engine
Pushes an unacknowledged stop from team lead to supervisor to plant manager on a fixed clock, so a stop never waits on someone remembering to call up the chain.
Response and repair tracking
Logs who responded, what action was taken, and when the line restarted, tied to the original event.
Downtime reason coding
Captures a standardized reason code at close, mechanical, material, quality, or changeover, so every stop rolls into the same taxonomy.
MTTR and OEE analytics
Rolls response time, repair time, and stop frequency into MTTR and OEE loss dashboards without a manual shift-end reconciliation.
Repeat-cause pattern tracking
Flags a station or cause code that recurs across shifts, so a chronic stop gets a corrective action instead of another log entry.
From request to system of record in four steps
Report
An andon pull or HMI trigger logs the station, line, and time the stop began.
Assess
If the team lead does not acknowledge inside the target window, the alert escalates automatically to the supervisor, then the plant manager.
Resolve
The responder records the action taken and confirms the line restart time against the original event.
Record
The stop closes with a standardized downtime reason code and feeds MTTR, OEE, and repeat-cause reporting.
What changes when andon escalation runs on Kissflow
| Process | Before Kissflow | On Kissflow |
|---|---|---|
| Line-stop notification | Travels by light, buzzer, or shout down the aisle | Logged automatically with station, line, and timestamp |
| Escalation | Depends on someone remembering to call up the chain | Escalates automatically by tier on a fixed response clock |
| Response tracking | No record of who responded or how long it took | Responder, action, and restart time logged against the event |
| Downtime reason | Guessed or reconstructed at shift end | Coded at close with a standardized reason taxonomy |
| MTTR and OEE reporting | Assembled days later in a spreadsheet | Rolled up automatically as each stop closes |
| Repeat-cause visibility | Chronic stops blend into the noise | Flagged automatically when a station or cause recurs |
Connects to the MES, SCADA, and ERP systems already running the line
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Built for how andon actually runs on the floor
An escalation layer, not a new andon system
Your andon lights, HMI, or SCADA stay the trigger. Kissflow runs the governed escalation, response tracking, and reporting around every pull.
Live in weeks, not a control-system project
Configure escalation tiers, response windows, and reason codes in the visual builder, without touching the machine layer.
Escalation that runs on a clock, not on memory
Unacknowledged stops move up the chain automatically once the response window lapses.
MTTR and OEE built in, not bolted on
Every stop closes into the same analytics layer, so response time and downtime loss are visible the same day, not the same month.
Repeat causes surface on their own
A station or cause code that keeps coming back gets flagged for corrective action instead of disappearing into a shift log.
Built for cross-shift accountability
Team leads, supervisors, and plant managers see the same event record with their own view of it, shift after shift.
Related apps
Downtime & Breakdown Reporting with RCA
Investigate the root cause of a breakdown once the andon escalation that flagged it is already closed.
OEE (Overall Equipment Effectiveness) Tracking
See how every logged line stop rolls into availability, performance, and quality loss at the equipment level.
Emergency Maintenance Orchestration Workflow
Coordinate the maintenance response itself when a line stop needs more than a quick fix.
We help manufacturing leaders keep the line moving when it matters most
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Talk to usGot questions? We're here to help.
Get SupportNo. Your andon lights, HMI, or SCADA layer stays the trigger. Kissflow runs the escalation, response tracking, and reporting workflow around the event it raises.
Downtime & Breakdown Reporting with RCA investigates why a stop happened after the fact. This app manages the stop in real time, from the pull to the tiered escalation to the line restart.
Any andon pull, HMI stop trigger, or manually logged stop on a monitored line, whether the cause is mechanical, material, quality, or changeover related.
Each tier gets a configurable response window. If the team lead does not acknowledge in time, the alert moves automatically to the supervisor, then the plant manager, without anyone placing a second call.
Yes. Process owners configure escalation tiers, response windows, and downtime reason codes in the visual builder, and the AI Builder can generate a working app from a plain-language description.
Through APIs and integration connectors, under single sign-on and role-based access, with every escalation and response written to an audit log.
Configuration and AI generation move delivery from weeks to days, without a control-system project or an engineering backlog.
Kissflow is certified to SOC 1, SOC 2, SOC 3, ISO/IEC 27001, HIPAA, GDPR, and CCPA, hosted on Google Cloud with data residency in the US, EU, APAC, and Oceania.
