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The usage of Poka-Yoka in industry 4.0 conditions

Wolniak Radosław

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

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2024

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z. 191

613--628

EN

Purpose: The purpose of this publication is to present the usage of Poka-Yoka approach in Industry 4.0 conditions. Design/methodology/approach: Critical literature analysis. Analysis of international literature from main databases and polish literature and legal acts connecting with researched topic. Findings: The integration of Poka-Yoke with Industry 4.0 signifies a transformative leap in error prevention methodologies, aligning seamlessly with the objectives of advanced manufacturing. By merging the principles of Poka-Yoke with smart technologies like sensors, IoT devices, and real-time data analytics, a dynamic and sophisticated approach to error prevention emerges in the era of Industry 4.0. With applications ranging from simple visual cues to complex technological solutions, Poka-Yoke finds resonance across various industries, particularly in the automotive sector, where sensors and devices on assembly lines swiftly detect and rectify deviations, elevating both product quality and operational efficiency. The incorporation of artificial intelligence and machine learning in Industry 4.0 augments Poka-Yoke, enabling systems not only to identify errors but also to learn from them, fostering continuous improvement and adaptability in response to evolving production scenarios. Emphasizing proactive error prevention at the source, continuous improvement, and a commitment to training and education, the key principles outlined in Table 1 contribute to creating resilient, reliable processes delivering consistently high-quality outputs. Table 2 demonstrates the seamless integration of Poka-Yoke with Industry 4.0, showcasing technological advancements that collectively form an adaptive approach to error prevention and quality management. Additionally, Table 3 highlights the advantages of this integration, emphasizing improved quality control, operational efficiency, and adaptability in modern manufacturing environments. However, challenges outlined in Table 4, including complex implementation, data security concerns, high initial costs, interoperability issues, and skill gaps, necessitate strategic planning and investment in overcoming obstacles. In conclusion, the integration of Poka-Yoke with Industry 4.0 signifies a strategic evolution, where technology-driven error prevention, continuous improvement, and a commitment to quality converge to create resilient, adaptive, and highly efficient manufacturing systems, positioning this integration as a cornerstone for excellence in the evolving landscape of industrial production. Originality/value: Detailed analysis of all subjects related to the problems connected with the usage of Poka-Yoka in Industry 4.0 conditions.

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The use of quality management tools to ensure safe working conditions at CO2 laser workstations

Ciecińska Barbara, Oleksiak Beata

Production Engineering Archives

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2023

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Vol. 29, Iss. 4

393-400

EN

Dynamic development of various technologies replacing existing, difficult or in various ways arduous, is the reason for replacing equipment with modern ones. New equipment may be associated with a different power supply, a different way that the construction materials are processed or the tools used, than the previous one. Then arises a need to re-examine whether the working conditions at a workplace are safe, what onerous and hazardous factors are associated with the work. An example of such a technological change could be a laser processing, when equipment using a concentrated energy stream, properly controlled, produces a specific effect on materials. However, along with the benefits of the new technology, come also many risks, such as the effects of radiation on matter and the human body, electricity, fire hazards, the problem of toxic emissions and others. This paper presents the problem of ensuring work safety at a newly commissioned CO2 laser station. Technique of brainstorming was used to identify and analyze the working conditions and types of hazards. These may be different from what was previously known, partially known, or even unconscious. Ishikawa diagram was developed and shown to be an effective tool for detailing and structuring problems in relation to safety. In the case of a technical problem, a poka-yoke solution to eliminate the hazard was proposed. Problems occurring at the workstation during machining and related to its operation were assigned, using the affinity diagram, to specific departments of the company, according to its work organization, which can significantly facilitate the management of the work and employees of the different departments in the future, in order to ensure safe and hygienic working conditions.

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The effect of lean tools on the safety level in manufacturing organisations

Ulewicz Robert, Lazar Livia V.

System Safety : Human - Technical Facility - Environment

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2019

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Vol. 1, nr 1

514--521

EN

Lean Management is currently one of the best-known and is the most widely used management concepts in production enterprises. Lean creates such a culture of work in an organization that makes all participants in the organization interested in raising the level of quality, reducing costs and delivery time. However, there is no information about the influence of lean tools on the level of safety in production organizations. The paper presents the influence of five lean tools on the safety level by the example of metal manufacturing organization. The number of potentially dangerous situations and the number of accidents were taken as the measure of safety level. The obtained results indicates that the most important for the safety level is 5S, TPM while Kaizen, Poka-Yoka and VSM are smaller. The paper aims to broaden the knowledge about the dependence of the use of lean tools on the level of occupational safety.

4

Proposition of Pick & Work system for application in manual assembly

Senderská K., Mareš A.

Zeszyty Naukowe Politechniki Rzeszowskiej. Mechanika

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2013

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z. 85[288], nr 2

179--186

EN

Many assembly processes in mechanical production systems have high share of manual operations. These manual operations can have big influence on final time and quality of production. Because the work is realized by human it is very important to take in account human properties and design the operation in way which will eliminate – mistakes and errors. To achieve this it is possible to use Poka-Yoke techniques and Pick-by systems. The paper describes the possibility of the use of these tools in assembly and proposes own Pick & Work system concept for application in the assembly operations.

PL

Większość procesów montażu w systemach produkcji mechanicznej składa się w znacznej części z operacji manualnych. Te operacje manualne mogą znacznie wpływać na końcowy czas i jakość produkcji. Ponieważ praca jest wykonywana przez człowieka, ważne jest uwzględnienie cech człowieka i projektowanie operacji, tak aby wyeliminować pomyłki i błędy. Aby to osiągnąć, możliwe jest użycie technik Poka-Yoke i systemów Pick-by. W pracy nakreślono możliwość wykorzystania tych narzędzi w montażu i zaproponowano system Pick & Work do zastosowania w operacjach montażu.