Production
https://prod.org.br/article/doi/10.14488/1980-5411.20260035
Production
Research Article

Mechanical error-proofing in CNC turning industrial validation of a Poka-Yoke device for scrap reduction

Vítor Alcácer; Rui Ferreira; David Mendes; João Costa

http://dx.doi.org/10.14488/1980-5411.20260035 Production, vol.36, e20260035, 2026
PDF
Downloads: 0
Views: 101

Abstract

Paper aims: To design and validate a mechanically integrated error-proofing mechanism capable of preventing incorrect center drill positioning during setup operations in Computer Numerical Control (CNC) turning environments, reducing scrap generation, and improving process reliability.

Originality: This study provides empirical industrial evidence on the implementation and quantitative validation of a mechanically integrated Poka-Yoke mechanism in CNC machining operations, preventing setup errors at the source through an intervention.

Research method: An industrial case study was conducted in an automotive component production line. The research included process observation, root-cause identification of setup variability associated with center drill positioning, and the design and implementation of a mechanical error-prevention device. Operational performance was evaluated through scrap rate and Overall Equipment Effectiveness (OEE) indicators using a before-and-after approach.

Main findings: Scrap was reduced from 1.18% to 0.56% (52.5%), while OEE increased from 85% to 90% (5 percentage points), indicating improvements in process stability and operational performance.

Implications for theory and practice: The study contributes empirical evidence to the literature on Poka-Yoke, preventive quality engineering, and source-level error prevention, while demonstrating the applicability of low-cost integrated interventions in machining environments. Findings also suggest that such mechanisms may complement digital quality systems within hybrid quality strategies.

Keywords

Manufacturing systems, Setup errors, Machining reliability, Operational performance, Tool positioning

References

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.

Belu, N., Ionescu, L. M., Misztal, A., & Mazăre, A. (2015). Poka Yoke system based on image analysis and object recognition. IOP Conference Series. Materials Science and Engineering, 95(1), 12138. https://doi.org/10.1088/1757-899X/95/1/012138.

Fontalvo Herrera, T. J., Banquez Maturana, A. G., & Mendoza Villero, K. (2024). Performance of a concurrent parallel production system through new operating curves of Six Sigma metrics. Production, 34, e20230040. https://doi.org/10.1590/0103-6513.20230040.

Franciosi, C., Di Pasquale, V., Iannone, R., & Miranda, S. (2019). A taxonomy of performance shaping factors for human reliability analysis in industrial maintenance. Journal of Industrial Engineering and Management, 12(1), 115-132. https://doi.org/10.3926/jiem.2702.

Friederich, J., & Lazarova-Molnar, S. (2024). Reliability assessment of manufacturing systems: a comprehensive overview, challenges and opportunities. Journal of Manufacturing Systems, 72, 38-58. https://doi.org/10.1016/j.jmsy.2023.11.001.

Helena, S. T., Camargo, V. R. S., Amaral, T. V. B., Szejka, A. L., Moura Leite, A. F. C. S., & Canciglieri, M. B. (2022). Interoperable data extraction and information enrichment system to support smart manufacturing: An experimental application on CNC machining lines of a healthcare product. Production, 32, e20210058. https://doi.org/10.1590/0103-6513.20210058.

Hofinger, G. (2018). Human Factors für Simulator trainings. In M. St.Pierre & G. Breuer (Eds.), Simulation in der Medizin: Grundlegende konzepte - Klinische anwendung (pp. 177-187). Berlin: Springer. https://doi.org/10.1007/978-3-662-54566-9_14.

Klages, B., & Zaeh, M. (2023). Concept of a data-based approach for the prediction and reduction of human errors in manual assembly. Procedia CIRP, 116, 209-214. https://doi.org/10.1016/j.procir.2023.02.036.

Kumar, R., Chauhan, P., Dwivedi, R., Singh, A., & Prasad, J. (2022). Design and development of ball dispenser machine through lean manufacturing tool Poka-Yoke technique in automobile industries. Materials Today: Proceedings, 62, 6530-6533. https://doi.org/10.1016/j.matpr.2022.04.335.

Li, N., Laux, C., & Antony, J. (2018). Designing for six sigma in a private organization in China under TQM implementation: a case study. Quality Engineering, 30(3), 405-418. https://doi.org/10.1080/08982112.2018.1475674.

Luiz, J. V. R., Souza, F. B., & Luiz, O. R. (2025). Theory of constraints and Industry 4.0: mutual contributions and research perspectives. Production, 35, e20250032. https://doi.org/10.1590/0103-6513.20250032.

Martinelli, M., Lippi, M., & Gamberini, R. (2022). Poka-Yoke meets deep learning: a proof of concept for an assembly line application. Applied Sciences, 12(21), 11071. https://doi.org/10.3390/app122111071.

Nallathambi, I., Savaram, P., Sengan, S., Alharbi, M., Alshathri, S., Bajaj, M., Aly, M. H., & El-Shafai, W. (2023). Impact of fireworks industry safety measures and prevention management system on human error mitigation using a machine learning approach. Sensors, 23(9), 4365. https://doi.org/10.3390/s23094365. PMid:37177567.

Ostadi, B., & Masouleh, M. S. (2019). Application of FEMA and RPN techniques for man-machine analysis in tobacco company. Cogent Engineering, 6(1), 1640101. https://doi.org/10.1080/23311916.2019.1640101.

Paolo, J., Gaiardelli, P., Powell, D., & Zanchi, M. (2022). Intelligent Poka-Yokes: error-proofing and continuous improvement in the digital lean manufacturing world. In D. Y. Kim, G. von Cieminski & D. Romero (Eds.), Advances in production management systems. Smart manufacturing and logistics systems: turning ideas into action (pp. 595-603). Cham: Springer Nature.

Pongboonchai-Empl, T., Antony, J., Neustock, J., Stemann, D., Komkowski, T., & Sony, M. (2025). DMAIC 4.0 in Action: introducing MSA 4.0 and Poka-Yoke 4.0. International Journal of Computer Integrated Manufacturing, 1-21. https://doi.org/10.1080/0951192X.2025.2599558.

Pötters, R. S. P., Schmitt, R., & Leyendecker, B. (2018). Effectivity of quality methods used on the shop floor of a serial production: how important is Poka-Yoke? Total Quality Management & Business Excellence, 29(9-10), 1200-1212. https://doi.org/10.1080/14783363.2018.1488559.

Prasad, M. M., Dhiyaneswari, J. M., Jamaan, J. R., Mythreyan, S., & Sutharsan, S. M. (2020). A framework for lean manufacturing implementation in Indian textile industry. Materials Today: Proceedings, 33, 2986-2995. https://doi.org/10.1016/j.matpr.2020.02.979.

Psarommatis, F., Prouvost, S., May, G., & Kiritsis, D. (2020). Product quality improvement policies in industry 4.0: characteristics, enabling factors, barriers, and evolution toward zero defect manufacturing. Frontiers of Computer Science, 2, 26. https://doi.org/10.3389/fcomp.2020.00026.

Psarommatis, F., & Azamfirei, V. (2024). Zero Defect Manufacturing: a complete guide for advanced and sustainable quality management. Journal of Manufacturing Systems, 77, 764-779. https://doi.org/10.1016/j.jmsy.2024.10.022.

Rahardjo, B., Wang, F.-K., Yeh, R.-H., & Chen, Y.-P. (2023). Lean manufacturing in industry 4.0: a smart and sustainable manufacturing system. Machines, 11(1), 72. https://doi.org/10.3390/machines11010072.

Saurin, T. A., Ribeiro, J. L. D., & Vidor, G. (2012). A framework for assessing poka-yoke devices. Journal of Manufacturing Systems, 31(3), 358-366. https://doi.org/10.1016/j.jmsy.2012.04.001.

Schmidt, F. C., Korzenowski, A. L., Goecks, L. S., Gomes, I. B., & Benetti, V. G. (2023). A Production System for the auto parts industry with elements of Industry 4.0. Production, 33, e20220005. https://doi.org/10.1590/0103-6513.20220005.

Shang, X., Ng, H. K. T., & Ling, M. H. (2023). On reliability analysis of one-shot devices with manufacturing defects. Quality Engineering, 35(1), 79-94. https://doi.org/10.1080/08982112.2022.2089855.

Sheikhalishahi, M., Eskandari, N., Mashayekhi, A., & Azadeh, A. (2019). Multi-objective open shop scheduling by considering human error and preventive maintenance. Applied Mathematical Modelling, 67, 573-587. https://doi.org/10.1016/j.apm.2018.11.015.

Silvestre, S. E. M., Chaicha, V. D. P., Merino, J. C. A., & Nallusamy, S. (2022). Implementation of a Lean Manufacturing and SLP-based system for a footwear company. Production, 32, e20210072. https://doi.org/10.1590/0103-6513.20210072.

Sopelana, A., Kunc, M., Rivera, O., Aranceta, J., & Rodriguez Castellanos, A. (2022). Modelling the dynamics of organisational change in a spanish industrial cooperative. The Journal of the Operational Research Society, 73(3), 455-466. https://doi.org/10.1080/01605682.2020.1860659.

Tommelein, I. D. (2019). Principles of mistake-proofing and inventive problem solving (TRIZ). In Proceedings of the 27th Annual Conference of the International Group for Lean Construction (IGLC) (pp. 1401-1412), Dublin, Ireland. Norway: International Group for Lean Construction. https://doi.org/10.24928/2019/0129.

Torres, Y., Nadeau, S., & Landau, K. (2021). Classification and quantification of human error in manufacturing: A case study in complex manual assembly. Applied Sciences, 11(2), 749. https://doi.org/10.3390/app11020749.

Trojanowska, J., Husár, J., Hrehova, S., & Knapčíková, L. (2023). Poka-Yoke in smart production systems with pick-to-light implementation to increase efficiency. Applied Sciences, 13(21), 11715. https://doi.org/10.3390/app132111715.

Velásquez, M., Zabala, N., Neira-Rodado, D., Baldovino, T. O., & Mercado-Caruso, N. (2022). Design of lean-based strategies to improve the flow of materials in the value chain of a furniture company in Colombia. Procedia Computer Science, 203, 502-507. https://doi.org/10.1016/j.procs.2022.07.070.

Vinod, M., Devadasan, S. R., Sunil, D. T., & Thilak, V. M. M. (2015). Six Sigma through Poka-Yoke: a navigation through literature arena. International Journal of Advanced Manufacturing Technology, 81(1), 315-327. https://doi.org/10.1007/s00170-015-7217-9.

Yin, R. K. (2025). Case study research and applications: design and methods (6th ed.). Thousand Oaks: Sage Publications.
 

Submitted date:
03/16/2026

Accepted date:
08/02/2026

6a9aaaeea9539534015689a4 production Articles
Links & Downloads
1980-5411 (Electronic) 0103-6513 (Printed)
Production ©2026 All rights reserved for this website content. Articles follow their own licenses.

Production

Share this page
Page Sections