Intelligent Poka-Yokes: Error-Proofing and Continuous Improvement in the Digital Lean Manufacturing World

Abstract

Poka-Yoke devices have always been regarded by lean manufacturing companies as essential quality control and assurance tools to support efficient and effective manufacturing processes and procedures. Thanks to their ease of use and low cost, these devices help maintain high-quality standards and also encourage organisations to undertake Kaizen continuous improvement activities. With the advent of new digital and analytical technologies, these devices have undergone significant transformations. Based on a study of the scientific literature and the results of brainstorming sessions conducted with factory managers and lean experts, this paper analyzes how and to what extent digitalization changes the definitions, functions, approaches, and perspectives of traditional Poka-Yokes. Furthermore, it examines how the change in data collection, sharing, analysis, processing, and feedback (interpretation) approaches brought by the digitalization and smartification of Poka-Yoke devices affects the operational performance of modern Digital Lean Cyber-Physical Production Systems.