Improving Metal Plate Utilization through IoT-Based Poka Yoke, AHP, and Ergonomic Design in an Electrical Transformer Company

Cosme-Rodriguez C.; MacEdo-Adrianzen J.; Gutierrez-Falcon P.C. · Proceedings of the 2025 IEEE 32nd International Conference on Electronics, Electrical Engineering and Computing, INTERCON 2025 (2025) · DOI: 10.1109/intercon67304.2025.11244685

Resumen

Metal casing manufacturing in the electrical transformer industry faces significant challenges related to material waste and ergonomic issues that impact both production and worker health. This study aims to improve sheet metal utilization by integrating Poka Yoke with loT-based systems, ergonomic workplace design, and the Analytic Hierarchy Process (AHP) for supplier selection. The results show substantial improvements in key indicators. Metal waste was reduced from 9.78% to 5.12%, exceeding the company's target of 6.51 %. Errors in the cutting process decreased from 2.80% to 0.47%, equivalent to an improvement of 83.21 %. Furthermore, the AHP method optimized supplier selection, reducing the percentage of factory-defective sheets from 4.10% to 2.63%. Regarding ergonomic design, ergonomic risk at the assembly station was reduced by 23.26%, going from a medium to a low level. These findings not only close the technical gap identified in the company, but also offer a replicable solution in other industries, improving the sector's competitiveness and safety.

Instituciones: Universidad Peruana de Ciencias Aplicadas