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Andon System

A complete production floor monitoring and alert management system. Tri-platform — WPF desktop display board, PHP web interface, and native Android mobile app — with ticketing, team chat, escalation, reports, USB GSM modem SMS, DKIM email signing, error monitoring, database management, and 4-level role-based access. 100% self-hosted, no third-party dependencies.

.NET 8.0 WPF PHP + MySQL Android (Java) REST API Self-Hosted USB GSM Modem DKIM Email

Tri-Platform Architecture

One backend, three interfaces — desktop, web, and mobile

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WPF Desktop Application

Full-featured production floor display board for wall-mounted monitors or workstations. Real-time status, ticketing, team chat, reports, and admin tools in a native Windows application.

.NET 8.0 • WPF • XAML • C#
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PHP Web Interface

Responsive web application accessible from any browser. Mobile-friendly design lets operators trigger alerts, supervisors manage tickets, and admins configure the system from any device.

PHP • MySQL • JavaScript • REST API
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Android Mobile App

Native Android application for on-the-go access. Operators can trigger alerts, supervisors manage tickets, and maintenance staff respond — all from their phone with push-style notifications.

Java • Android SDK 34 • Material Design

Features

Everything you need to manage production floor alerts and maintenance

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Andon Ticketing System

Four color-coded ticket types with a full lifecycle from creation through acknowledgment to completion.

  • Machine Down (critical)
  • Planned Downtime
  • Running with Problems
  • Changeover
  • Visual button states (opacity indicates status)
  • Description text & maintenance notification flag
  • Cancel with reason tracking
  • Duplicate ticket prevention
  • Full lifecycle: Created → Acknowledged → Completed
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3-Tier Auto-Escalation

Unresolved tickets automatically escalate through three tiers with configurable time thresholds per ticket type.

  • Tier 1: Maintenance team notified immediately
  • Tier 2: Supervisor notified (default 45 min)
  • Tier 3: Plant supervisor notified (default 90 min)
  • Configurable thresholds per ticket type
  • MySQL Event Scheduler (checks every 5 min)
  • Admin panel for rule management
  • Escalation statistics & tracking
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Hierarchical Location Management

Organize your facility in a three-level hierarchy for precise alert targeting.

  • Building → Area → Location tree structure
  • Interactive sidebar navigation
  • Create & manage locations (Supervisor+)
  • User-to-area assignments for targeted notifications
  • Multi-area assignment support
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Email & SMS Notifications

Keep your maintenance team informed with automatic alerts via SMTP email with DKIM signing, SMS-via-email gateways, or direct USB GSM modem SMS.

  • Email notifications (direct SMTP with TLS/SSL)
  • DKIM email signing for improved deliverability
  • SMS via carrier email-to-text gateways
  • USB GSM modem SMS (SIM7600G-H / SIM800)
  • Pure PHP serial AT commands — no external tools
  • Area-specific targeting
  • Configurable quiet hours
  • Emergency override for critical alerts
  • Per-user notification preferences
  • Full notification log & delivery tracking
  • All major US carriers supported
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Team Chat & Ticket Comments

Real-time communication between operators, maintenance, and supervisors.

  • Channel-based team messaging
  • Direct messages between users
  • Ticket-specific comment threads
  • Internal notes (supervisor+ only)
  • Unread message counts
  • Shift handoff communication
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Reports & Analytics

Six comprehensive report types with print capability on both platforms.

  • Summary Report (tickets, response times, downtime)
  • Downtime Analysis (top locations, daily trends)
  • Performance Report (worker metrics, response distribution)
  • Parts Usage Report (inventory insights)
  • Repeat Issues Report (recurring problems)
  • Trends Report (daily patterns over time)
  • Configurable time periods (7d, 30d, 90d, 1yr)
  • Print-optimized output
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User Management

Full user lifecycle management with role-based access on both platforms.

  • Create, edit, activate/deactivate users
  • 4 role levels with automatic tab visibility
  • Password reset
  • Last login tracking
  • Status & role badges
  • bcrypt password hashing
  • 24-hour session tokens
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Real-Time Performance Metrics

Live dashboard metrics displayed directly on the Supervisor tab.

  • Average response time
  • Ticket completion rate
  • Total downtime hours
  • Active worker count
  • Response time distribution (color-coded)
  • Top 5 performers leaderboard
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Modem Troubleshooting & Diagnostics

Built-in admin tool for diagnosing USB GSM modem connectivity, signal quality, and SMS delivery.

  • One-click modem status check
  • Signal strength with RSSI & dBm readout
  • SIM card & network registration status
  • Modem manufacturer, model & firmware info
  • Interactive AT command console
  • Quick-access buttons for common AT commands
  • Send test SMS directly from the admin panel
  • Safety-blocked dangerous commands
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Database Management

Admin tools for monitoring database health, performing backups, and cleaning up old data.

  • Table-level size & row count stats
  • Total database size overview
  • Data cleanup & purge tools
  • Backup & restore functionality
  • Backup history tracking
  • Table optimization
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Server Error Monitoring

Automatic capture and alerting for server errors, API failures, modem issues, and SMTP problems.

  • Automatic error capture & logging
  • Categorized error types (API, modem, SMTP)
  • Severity-level tracking
  • Opt-in email/SMS error alerts for admins
  • Error dashboard with filtering
  • Resolution tracking & history
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Administration & Configuration

Full system control for administrators with web and desktop interfaces.

  • Escalation rule management
  • User area assignments
  • System settings & configuration
  • Modem troubleshooting & AT console
  • Database management & backups
  • Server error monitoring dashboard
  • DKIM & SMTP email configuration
  • USB modem COM port configuration
  • Web installer for easy setup
  • Built-in diagnostics page
  • Database schema auto-import

4-Level Role-Based Access

Tabs and features are automatically shown or hidden based on the logged-in user's role

Feature Production (L1) Supervisor (L2) Maintenance (L3) Admin (L4)
Production Monitor & Trigger Alerts ✓ ✓ ✓ ✓
Create & Cancel Tickets ✓ ✓ ✓ ✓
Team Chat & Messages ✓ ✓ ✓ ✓
Acknowledge & Complete Tickets ✗ ✓ ✓ ✓
Supervisor Dashboard & Metrics ✗ ✓ ✓ ✓
Reports & Analytics ✗ ✓ ✓ ✓
Maintenance Tab & Tracking ✗ ✗ ✓ ✓
Manage Locations ✗ ✗ ✗ ✓
User Management ✗ ✗ ✗ ✓
Escalation Configuration ✗ ✗ ✗ ✓
System Settings & Full Control ✗ ✗ ✗ ✓
Modem Diagnostics & AT Console ✗ ✗ ✗ ✓
Database Management & Backups ✗ ✗ ✗ ✓
Error Monitoring Dashboard ✗ ✗ ✗ ✓

System Architecture

Location hierarchy and component overview

ANDON SYSTEM 💻 WPF Desktop App .NET 8.0 · C# · XAML 🌐 PHP Web Interface PHP · JS · HTML/CSS 📱 Android App Java · Android SDK 34 REST API Token Auth · JSON · CORS 🗂 MySQL Database InnoDB · Event Scheduler LOCATION HIERARCHY 🏢 Building 1 Area 1 📍 Machine 1 🏢 Building 2 Area 2 📍 Machine 1 📍 Machine 2 🔔 Notifications SMTP · DKIM USB Modem · SMS 🚨 Error Monitor API · Modem · SMTP

Technical Details

Built with proven technologies for reliability and performance

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Requirements

  • PHP 7.4+ with PDO MySQL extension
  • MySQL 5.7+ with Event Scheduler
  • .NET 8.0 Runtime (WPF app)
  • Windows 10/11 (WPF app)
  • Any modern browser (web interface)
  • Apache or IIS (production web server)
  • SIM7600G-H or SIM800 USB modem (optional, for direct SMS)
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Security

  • bcrypt password hashing
  • Token-based session authentication
  • 24-hour session expiry
  • Role-based access on all endpoints
  • Input validation & sanitization
  • CORS enabled for API access
  • DKIM email signing for deliverability
  • Dangerous AT commands blocked in modem console
  • HTTPS recommended for production
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Database

  • users & user_roles
  • buildings, areas, locations
  • tickets & ticket comments
  • messaging channels & messages
  • notification settings & log
  • escalation rules & history
  • andon_alerts & status_types
  • server_error_log
  • system_settings (modem, DKIM, SMTP config)

Ready to Modernize Your Production Floor?

Get in touch to discuss how the Andon System can be tailored to your facility's needs.

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