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The usage of Poka-Yoka in industry 4.0 conditions

Wolniak Radosław

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

2024

z. 191

613--628

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.