4 Practical Ways to Improve Efficiency, Quality, and Reduce Waste
If you're a small business owner struggling to grow or adapt to change, you're not alone. Many businesses face operational inefficiencies, customer complaints, and challenges in scaling sustainably. One of the best ways to shift this pattern is by adopting a continuous improvement mindset—and one powerful concept from the world of lean manufacturing can help you do just that.
What Is the Andon Switch?
When I joined Herman Miller—known for its design innovation and operational excellence—I experienced one of the best onboarding programs. Part of that experience included touring the manufacturing floor and learning about the Herman Miller Performance System (HMPS), which was inspired by Toyota’s Total Quality Management.
That’s where I first encountered the Andon Switch. It’s a simple but transformative tool: a button or cord on the factory floor that workers can pull when they spot a problem—like a product defect, a process delay, or a safety issue. Pulling the cord pauses production and calls in support to resolve the issue immediately.
But here’s what makes it revolutionary: it empowers everyone to identify problems early, fix them fast, and continuously improve. No blame. Just better systems.
So, how can a small business apply the Andon Switch—without a factory or assembly line?
You don’t need a manufacturing floor to adopt this mindset. What you need is the willingness to pause, reflect, and improve—every single day.
Here are four practical ways to "flip the Andon Switch" in your small business to increase efficiency, improve quality, and reduce waste.
- Create a Clear Path for Team Feedback—And Act on It
In any business, your team often sees problems before you do. Just like a factory worker pulling the Andon cord, your employees need a safe, structured way to speak up when something isn’t working.
Application for small business efficiency:
Set up regular feedback loops—like weekly check-ins or anonymous surveys—to surface issues. But don’t stop there. Act on what you hear. Look for patterns in complaints, confusion, or inefficiencies. Show your team that their input matters. Build a continuous improvement mindset.
Example: A barista tells you customers are confused by the café’s menu layout, which slows down service. Instead of dismissing the comment, test a simplified version for a week. Track order time and customer feedback. This is what continuous improvement looks like in action.
- Audit Repetitive Tasks for Friction
In lean systems, any action that doesn’t directly add value to the customer is considered waste. In a small business, this often shows up in repetitive tasks that eat time and energy.
Application to reduce waste in small business:
Identify high-frequency tasks in your daily or weekly routines. Then, ask: Can this be automated, templatized, or eliminated? How can I improve workflow automation in my small business?
Example: If customer-facing staff are typing out the same responses repeatedly think task automation, create templated email signatures or pre-written replies. Or, build a quick-reference FAQ for your team. Better yet, involve your team—ask them where they feel stuck or inefficient. That’s where you can expose hidden waste.
- Catch Small Errors Before They Become Big Problems
Just like the Andon Switch stops a bad product before it continues down the line, early problem detection can save your small business time, money, and reputation.
Application for small business process improvement:
Develop checklists or pre-delivery reviews for your services. Don’t let preventable errors damage your brand.
Example: A freelance designer or consultant can implement a checklist before sending deliverables—checking for typos, consistency, and alignment with brand voice. One minute of review can prevent hours of revisions, lost client trust, or refunds.
- Make Continuous Improvement a Shared Habit
The real power of the Andon system is cultural. Everyone is responsible for making things better—not just management.
Application for small business owners:
Build a culture where small, consistent changes are expected and celebrated. Make improvement part of your weekly rhythm.
Example: In your staff meeting (or even a solo weekly review), ask:
- What didn’t go smoothly last week?
- What repeat complaint or bottleneck showed up?
- What’s one small improvement we can test this week?
Capture it. Test it. Share the results. Continuous improvement becomes contagious when it’s visible and simple.
Final Thoughts: Small Tweaks, Big Impact
You might not have a literal Andon cord in your business—but you can adopt the Andon mindset every day.
Whether you're running a café, a design studio, a wellness practice, or a retail store, the key to growth isn't always big changes. It’s small, thoughtful improvements made consistently—reducing friction, catching errors early, and involving your team in smarter ways of working.
By flipping the Andon Switch in your small business, you’ll build a leaner, more efficient, and more resilient operation—one where growth isn’t just possible, it’s inevitable.
Looking to Build a Smarter, More Agile Business?
At Go to Eleven Consulting, we help small businesses implement strategies that amplify growth, reduce waste, and improve customer experience. Let’s flip your Andon Switch together.
✅ Book a free 30-minute strategy session today.
