Poka-Yoke Model for Controlling Unit Entering and Fall Reduction in the Transportation of Toilets

Abstract

Small and medium toilet manufacturing businesses in Peru face significant problems such as low productivity because of a high rate of production losses. To address this issue, the present study proposes the application of a lean manufacturing technique, such as the Poka-Yoke model, which improves the production flow within the company by implementing a transportation cart with a safety system to help reduce material falls during the manufacturing process. The results showed a 24% increase in productivity and reduction in problems of damaged products that did not meet quality standards, thus preventing their subsequent reprocessing.