Novel POKA-YOKE approaching toward industry-4.0: A literature review

  • Sugiri Widjajanto Industrial Engineering, Universitas Mercu Buana Jakarta, Indonesia
  • Humiras Hardi Purba Industrial Engineering, Universitas Mercu Buana Jakarta, Indonesia
  • Sansuri Choesnul Jaqin Industrial Engineering, Universitas Mercu Buana Jakarta, Indonesia
Keywords: Poka-yoke, mistake-proof, fault-proof, Industry4.0

Abstract

Understanding quality in manufacturing starts with learning why errors happen and this could be improved by analysis with root causes related to human errors. Human reliability influenced by equipment design or working environment will come to concept of poka-yoke (mistake proofing), and various means to reduce mistakes that have been greatly improved recently with latest sophisticated technology. This article will discuss poka-yoke technology related to the Industry 4.0 (I4.0) or Smart Manufacturing concept. The method is to review research articles published within 2015-2020 with a keyword poka-yoke or mistake-proof or fault-proof and verify further whether their poka-yoke tools have implemented the I4.0 concept. The results obtained 50 selected articles, with 13 of them that already applied information technology, cloud computing, and augmented reality, which are considered as I4.0 tools. However, its application is not always satisfying concerning its suitability function, requirement of industries, culture, local regulation, and internal business concern, especially in terms of efficiency and cost.

References

Ahmed, M. B., Sanin, C., & Szczerbicki, E. (2019). Smart virtual product development (SVPD) to enhance product manufacturing in industry 4.0. Procedia Computer Science, 159(2018), 2232–2239. https://doi.org/10.1016/j.procs.2019.09.398

Alghozali, F. I., Jamaludin, R., & Bahaudin, A. Y. (2016). Enhancing Quality of Service: A Conceptual Poka-Yoke Approach. Journal of Technology and Operations Management, 11(2), 47–56.

Antonelli, D., & Stadnicka, D. (2016). Classification and efficiency estimation of mistake proofing solutions by Fuzzy Inference. IFAC-PapersOnLine, 49(12), 1134–1139. https://doi.org/10.1016/j.ifacol.2016.07.651

Antonelli, D., & Stadnicka, D. (2019). Predicting and preventing mistakes in human-robot collaborative assembly. IFAC-PapersOnLine, 52(13), 743–748. https://doi.org/10.1016/j.ifacol.2019.11.204

Antonelli, Dario, & Astanin, S. (2015). Enhancing the quality of manual spot welding through augmented reality assisted guidance. Procedia CIRP, 33, 556–561. https://doi.org/10.1016/j.procir.2015.06.076

Ardi, S., & Abdurrahman, H. (2017). Design of pokayoke systems to increase the efficiency of function check oxygen sensor machine using programmable logic controller in manufacturing industry. Proceedings - 2017 4th International Conference on Information Technology, Computer, and Electrical Engineering, ICITACEE 2017, 2018-Janua, 192–196. https://doi.org/10.1109/ICITACEE.2017.8257701

Ardi, S., Nurdin, M. A. R., & Ponco, A. (2018). Design of pokayoke system on the process of mounting actuator bracket based on programmable logic controller in automotive manufacturing industry. MATEC Web of Conferences, 197, 4–7. https://doi.org/10.1051/matecconf/201819714014

Attia, E., Khader, K., & Nada, O. (2019). Mistake Proofing Cam Mechanism Through Six-sigma Process: Case Study on Clothes Printing Machines. International Journal of Engineering, 32(3), 438–444.

Bajjou, M. S., & Chafi, A. (2018). Lean construction implementation in the Moroccan construction industry. Journal of Engineering, Design and Technology, 16(4), 533–556. https://doi.org/10.1108/JEDT-02-2018-0031

Bici, M., Broggiato, G. B., Campana, F., & Dughiero, A. (2017). Computer Aided Inspection Procedures to Support Smart Manufacturing of Injection Moulded Components. Procedia Manufacturing, 11(June), 1184–1192. https://doi.org/10.1016/j.promfg.2017.07.243

Che-Ani MN., AS., S., IA, A., & S., K. (2017). Solving Production Processes Disparity Issue through Implementation of Poka-Yoke Concept. International Journal of Materials, Mechanics and Manufacturing, 5(4), 278–281. https://doi.org/10.18178/ijmmm.2017.5.4.333

Dahivale, R. P., & Lokhande, H. (2020). Operational process improvement by eliminating rejections and avoiding scrap by implementing “poka-Yoke.” Our Heritage UGC Care Listed Journal, 68(49), 46–52.

Dawood, S. A., Elsayed, E. A., Rahaman, A., & Karthikeyan, R. (2018). Role of Lean Manufacturing Tools in Soft Drink Company. SSRG International Journal of Mechanical Engineering, 5(1), 1–7.

Erdogan, S., Quesada-Pineda, H., & Bond, B. (2017). An empirical tool to measure the effectiveness of Kaizen events: A case study in the wood products industries. Forest Products Journal, 67(3–4), 164–178. https://doi.org/10.13073/FPJ-D-16-00044

Fauzan, M. R., Poeri, P., Iqbal, M., & Defect, W. (2016). Usulan Perbaikan Proses Pencetakan Motif Pada Kain Grey Untuk Meminimasi Waste Defect Di Pt. Kharisma Printex Dengan Pendekatan Lean Manufacturing Improvement Proposal of Motifs Printing Processing At Pt Kharisma Printex for Minimizing Waste Defect Using. E-Proceeding of Engineering, 3(2), 2974–2981.

Gavriluţă, A., Niţu, E. L., Gavriluţă, A., Anghel, D. C., Stănescu, N. D., Radu, M. C., CreȚu, G., BiriȘ, C. M., & Păunoiu, V. (2018). the Development of a Laboratory System To Experiment Methods To Improve the Production Flows. Proceedings in Manufacturing Systems, 13(3), 127–132. https://search.proquest.com/docview/2137835746?accountid=26642%0Ahttp://link.periodicos.capes.gov.br/sfxlcl41?url_ver=Z39.88-2004&rft_val_fmt=info:ofi/fmt:kev:mtx:journal&genre=article&sid=ProQ:ProQ%3 Aengineeringjournals&atitle=THE+DEVELOPMENT+OF+A+LABORA

Hoellthaler, G., Braunreuther, S., & Reinhart, G. (2019). Requirements for a methodology for the assessment and selection of technologies of digitalization for lean production systems. Procedia CIRP, 79, 198–203. https://doi.org/10.1016/j.procir.2019.02.046

Hudori, M., Simanjuntak, J. M., & Belakang, L. (2017). Poka Yoke untuk Pembuatan Palet Package Information di Bagian Shipping. Industrial Engineering, 6(1), 16–21.

Isnain, S. K., & Karningsih, P. D. (2016). Perancangan Perbaikan Proses Produksi Komponen Bodi Mobil Daihatsu dengan Lean Manufacturing di PT. “XYZ.” Jurnal Studi Manajemen Dan Bisnis, 3(2), 144–156.

Kumar, B., & Kumar, P. (2017). Implementation of Poka Yoke in Needle Bearing Assembly Process. International Journal of Engineering Science Invention, 6(11), 1–10.

Kumar, M., Vaishya, R., & Parag. (2018). Real-time Monitoring System to Lean Manufacturing. Procedia Manufacturing, 20, 135–140. https://doi.org/10.1016/j.promfg.2018.02.019

Kumar, S., Dhingra, A., & Singh, B. (2018). Lean-Kaizen implementation: A roadmap for identifying continuous improvement opportunities in Indian small and medium sized enterprise. Journal of Engineering, Design and Technology, 16(1), 143–160. https://doi.org/10.1108/JEDT-08-2017-0083

Kurdve, M. (2018). Digital assembly instruction system design with green lean perspective-Case study from building module industry. Procedia CIRP, 72, 762–767. https://doi.org/10.1016/j.procir.2018.03.118

Kurdve, M., Hildenbrand, J., & Jönsson, C. (2018). Design for green lean building module production - Case study. Procedia Manufacturing, 25, 594–601. https://doi.org/10.1016/j.promfg.2018.06.096

Kurhade, A. J. (2015). Review on “Poka-Yoke: Technique to Prevent Defects.” International Journal Of Engineering Science & Research Technology, 4(11), 652–659.

Lazarevic, M., Mandic, J., Sremcev, N., Vukelic, D., & Debevec, M. (2019). A systematic literature review of poka-yoke and novel approach to theoretical aspects. Strojniski Vestnik/Journal of Mechanical Engineering, 65(7–8), 454–467. https://doi.org/10.5545/sv-jme.2019.6056

Lemahieu, P. G., Nordstrum, L. E., & Greco, P. (2017). Lean for education. Quality Assurance in Education, 25(1), 74–90. https://doi.org/10.1108/QAE-12-2016-0081

Lilja, E. (2018). Poka-yoke design of rubber rail for holding and transversal sealing of packages. 1–57.

Malega, P. (2018). Poka – Yoke – solution to human errors in the production process. International Journal of Business Management and Technology, 2(5), 207–213.

Mayr, A., Weigelt, M., Kühl, A., Grimm, S., Erll, A., Potzel, M., & Franke, J. (2018). Lean 4.0-A conceptual conjunction of lean management and Industry 4.0. Procedia CIRP, 72, 622–628. https://doi.org/10.1016/j.procir.2018.03.292

Muharam, M., & Latif, M. (2019). Design of poka-yoke system based on fuzzy neural network for rotary- machinery monitoring Design of poka-yoke system based on fuzzy neural network for rotary-machinery monitoring. Materials Science and Engineering, 1–9. https://doi.org/10.1088/1757-899X/602/1/012003

Pötters, P., Schmitt, R., & Leyendecker, B. (2018). Total Quality Management & Business Excellence Effectivity of quality methods used on the shop floor of a serial production – how important is Poka Yoke? Total Quality Management, 29(10), 1200–1212. https://doi.org/10.1080/14783363.2018.1488559

Prayogi, E., Setiadi, D. K., Pancasila, U., & Teknik, F. (2018). Perancangan Sistem Pokayoke Untuk Part Smart Key Pada Proses Perakitan Mobil di PT. XYZ. Seminar Rekayasa Teknik, 575–583.

Putri, D. R., & Handayani, W. (2019). Zero Defect Pada Produksi Kantong Kraft Melalui Metode Poka Yoke Di Pt. Industri Kemasan Semen Gresik. Jurnal MEBIS (Manajemen Dan Bisnis), 4(1), 44–58. https://doi.org/10.33005/mebis.v4i1.52

Qeshmy, D. E., Makdisi, J., Da_Silva, E. H. D. R., & Angelis, J. (2019). Managing Human Errors: Augmented Reality Systems as a tool in the quality journey. Procedia CIRP, 28, 24–30. https://doi.org/10.1016/j.promfg.2018.12.005

Rojo Abollado, J., Shehab, E., & Bamforth, P. (2017). Challenges and Benefits of Digital Workflow Implementation in Aerospace Manufacturing Engineering. Procedia CIRP, 60, 80–85. https://doi.org/10.1016/j.procir.2017.02.044

Romero, D., Gaiardelli, P., Powell, D., Wuest, T., & Thürer, M. (2019). Rethinking jidoka systems under automation & learning perspectives in the digital lean manufacturing world. IFAC-PapersOnLine, 52(13), 899–903. https://doi.org/10.1016/j.ifacol.2019.11.309

Rösiö, C., Aslam, T., Srikanth, K. B., & Shetty, S. (2019). Towards an assessment criterion of reconfigurable manufacturing systems within the automotive industry. Procedia Manufacturing, 28, 76–82. https://doi.org/10.1016/j.promfg.2018.12.013

Rubio-Romero, J. C., & Pardo, C. (2019). Poka-Yokes as Occupational Preventive Measures in Construction Safety. A Review. Nature, 556–562.

Saputra, T. M., Hernadewita, H., Yudha, A., & Saputra, P. (2019). Quality Improvement of Molding Machine through Statistical Process Control in Plastic Industry. Journal of Applied Research on Industrial Engineering, 6(2), 87–96. https://doi.org/10.22105/jarie.2019.163584.1068

Satolo, E. G., Leite, C., Goes, G. A., & Salgado, D. D. A. (2018). Ranking lean tools for world class reach through grey relational analysis. Grey Systems: Theory and Application, 8(4), 399–423. https://doi.org/10.1108/GS-06-2018-0031

Schaede, C., Seifermann, S., & Metternich, J. (2018). Automated generation of CNC programs for manufacturing of individualized products. Procedia CIRP, 72, 1251–1257. https://doi.org/10.1016/j.procir.2018.03.064

Selvam, R., & Loganathan, G. B. (2019). Product detail and analysis of hydraulic quick releasing coupling. Materials Today: Proceedings, 22, 751–755. https://doi.org/10.1016/j.matpr.2019.10.081

Shrigadi, S. S., Pol, S. P., & Joshi, A. K. (2015). Poka-Yoke: Mistake Proofing To Achieve Zero Defects. International Journal of Innovation in Engineering, Research and Technology (IJIERT), 1–6.

Singh, J., & Singh, H. (2015). Performance Enhancement of a Manufacturing Unit of Northern India Using Continuous Improvement Strategies — A Case Study. Productivity, 56(1), 88–96.

Solaimani, S., & Sedighi, M. (2020). Toward a holistic view on lean sustainable construction: A literature review. Journal of Cleaner Production, 248, 119213. https://doi.org/10.1016/j.jclepro.2019.119213

Soni, P., & Yadav, T. (2018). Review Paper on “Productivity Improvement by using Poka-Yoke.” IRJET, 5(12), 761–763.

Sundaramali, G., Abinav Shankar, S., & Manoj Kummar, M. (2018). Non-conformity recovery and safe disposal by Poka Yoke and hallmarking in a piston unit. International Journal of Productivity and Quality Management, 24(4), 460–474. https://doi.org/10.1504/IJPQM.2018.093445

Tak, P. D., & Wagh, S. S. (2015). Poka Yoke Implementation on Punching Machine: a Case Study. International Journal of Research in Engineering and Technology, 04(02), 98–106. https://doi.org/10.15623/ijret.2015.0402014

Tezel, A., & Aziz, Z. (2017). Benefits of visual management in construction: cases from the transportation sector in England. Construction Innovation, 17(2), 125–157. https://doi.org/10.1108/CI-05-2016-0029

Thareja, P. (2016). Poka Yoke: Poking into Mistakes for Total Quality! OmniScience: A Multi-Disciplinary Journal, 6(2), 1–8.

Vinayagasundaram, R. Velmurugan, C. (2018). IMPLEMENTATION OF ZERO DEFECT THROUGH POKA YOKE APPROACHES. International Journal of Pure and Applied Mathematics, 119(17), 2319–2332.

Published
2020-11-12
How to Cite
Widjajanto, S., Purba, H. H., & Jaqin, S. C. (2020). Novel POKA-YOKE approaching toward industry-4.0: A literature review. Operational Research in Engineering Sciences: Theory and Applications, 3(3), 65-83. Retrieved from https://oresta.rabek.org/index.php/oresta/article/view/71