VINOD KUMAR, NIHAL ANWAR SIDDIQUI AND PRASENJIT MONDAL
Abstract
The study explores to ensuring worker safety and removing process hazards are crucial in the quickly changing manufacturing sector. For the transition from worker compliance to engineering-based safety solutions, this study investigates the Japanese âmistake-proofingâ method known as Poka-Yoke. The goal of the research is to create Poka-Yoke mechanisms that are incorporated into manufacturing systems and backed by standardized safety procedures that have been verified by coding and simulation. A literature review, a mathematical model, and MATLAB Simulink simulations are all components of a multifaceted approach. Real-time control system responses, reliability functions, and hazard detection probabilities are the main areas of focus. The suggested safety measures were validated by simulating real-world manufacturing in Simulink scenarios. Algorithms reduced worker dependence by enabling sensor-based error detection, control system responses, and automated shutdowns. Simulation results and literature comparisons revealed enhanced error detection, increased reliability, and quicker reaction times. Simulink diagrams highlighted differences in system behaviour.