On most shop floors the real production status lives in someone's head, on a whiteboard, or three clicks deep inside a Work Order that nobody on the line can see. ERPNext Manufacturing tracks the transactional truth — Work Orders, Job Cards, operations, and Material Requests — but it has no full-screen Andon board, no physical call-for-help signaling, and no live takt-versus-actual pace indicator. When a machine stops or a line runs out of material, the clock keeps running while someone walks to find a supervisor. That reaction gap is exactly where lean visual management is supposed to win, and it is where ERPNext core runs out of road.

We build a proper Frappe app — say ecosire_andon — that installs cleanly onto your existing ERPNext v15 or v16 bench without forking core. It ships new DocTypes such as Andon Station, Andon Call, and Andon Escalation Rule, plus a full-screen board rendered as a Frappe web page / workspace that reads live from your Work Order, Job Card, and Workstation records. Operators raise calls from a wall-mounted tablet or a hardware button (via a whitelisted REST endpoint), and the board recolors in real time — green for running to takt, amber for a raised call, red for a confirmed stoppage. Takt time is computed from the Work Order planned quantity and shift calendar; actual pace comes off Job Card time logs and completed-qty updates, so the board shows whether the cell is ahead or behind without anyone keying in a number.

Under the hood it is standard, upgrade-safe Frappe engineering. hooks.py doc events on Job Card and Stock Entry update station state on submit; server scripts and whitelisted methods (@frappe.whitelist()) expose the call, acknowledge, and resolve actions to the buttons and tablets; client scripts drive the auto-refresh and color logic on the board; and a scheduler event walks open Andon Call records every minute to fire escalation timers — routing a notification (email, ERPNext notification, or webhook to Slack/Teams/an SMS gateway) up the chain when a call is not acknowledged inside its SLA. Access is governed by ERPNext role profiles and permissions, so operators, line leads, and maintenance each see and act on only what their role allows, and every call, acknowledgement, and resolution is a queryable record for later Pareto and MTTR analysis rather than a lost event.

Because this is build-to-order, nothing is generic. We start from a short scoping call, map it to your line and cell layout, your stoppage reason codes, your escalation chain and shift patterns, then build against a copy of your data. You get the installable source for your version of the app, deployed and configured on your bench, with UAT on a staging site before anything touches production.

Delivery typically runs one working week from confirmed scope — not an instant marketplace download, because we are building and validating this against your actual manufacturing setup. You receive the git repository, technical and user documentation, a training session for supervisors and operators, and a post-go-live support window so the boards are trusted and used from day one.