Development of a new expandable Andon light system into lean manufacturing production using MQTT and smart bulbs

Abstract

n an era of constant technological advancement, manufacturing industries are witnessing transformative changes. The traditional Andon system, once a cornerstone of lean manufacturing through visual and auditory cues, now faces the need for modernization in today’s interconnected production facilities. This thesis explores the development and implementation of an advanced Andon light system in the context of in-house logistics and manufacturing. It addresses the need for an updated system to replace outdated hardware and software. Using MQTT as a lightweight communication protocol and smart bulbs with Zigbee technology, the research focuses on improving system efficiency and versatility. The study presents the development of a solution which offers the traditional Andon light system features with support for diverse applications. This thesis relies primarily on experimental research to address the development of the Andon system. The research encompasses critical decisions regarding the choice of communication protocol, specifically among MQTT, HTTP, and WebSockets. Additionally, the selection of system hardware is examined, with a comparative analysis between conventional Andon light posts and smart bulbs. Each choice is meticulously explained based on its features and implications. Further on the development process and the architecture of the system is explained in-depth. The system presented in this thesis prioritizes cost-efficiency, resulting in the utilization of two smart bulbs per manufacturing cell. This decision posed a significant challenge due to the complexities in managing colors within these two bulbs. While not directly applicable as traditional Andon lights, this thesis explores alternative applications for the system, emphasizing its potential for expansion within logistics and observability.