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This study investigates the impact of Lean methodologies - Poka Yoke, 5S, and Standardized Work Analysis Board (SAB) - on productivity, efficiency, and error rates in a human-robot collaborative workspace. A controlled experiment was conducted with 30 participants performing manual assembly tasks in two scenarios: a baseline condition without Lean interventions and an optimized condition incorporating these methods. Poka Yoke mechanisms were implemented to prevent errors during assembly, ensuring correct task execution. The 5S method organized the workspace, minimizing non-value-added activities such as tool searching and material handling. SAB facilitated standardized workflows, reducing process variability and improving synchronization between human and robotic elements. The results showed a significant increase in productivity, with task completion times reduced by 25%, primarily due to the improved organization and flow achieved through 5S. Efficiency gains were observed through consistent task performance enabled by SAB, while the error rate decreased by 40% due to Poka Yoke’s error-proofing mechanisms. These findings highlight the potential of Lean methods to enhance the effectiveness of human-robot collaboration by addressing inefficiencies, standardizing workflows, and reducing errors. This study underscores the value of integrating Lean principles into hybrid work environments to optimize performance and quality in industrial applications.

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Enhancing Productivity and Reducing Error Rates in Human-Robot Collaboration Through Lean Methodologies: A Comparative Study of Poka Yoke, 5S, and Standard Work Sheet

  • 会议论文

  • 发表日期：

    2025年

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  • Patrick Poetters,
  • Sumona Sen

摘要

This study investigates the impact of Lean methodologies - Poka Yoke, 5S, and Standardized Work Analysis Board (SAB) - on productivity, efficiency, and error rates in a human-robot collaborative workspace. A controlled experiment was conducted with 30 participants performing manual assembly tasks in two scenarios: a baseline condition without Lean interventions and an optimized condition incorporating these methods. Poka Yoke mechanisms were implemented to prevent errors during assembly, ensuring correct task execution. The 5S method organized the workspace, minimizing non-value-added activities such as tool searching and material handling. SAB facilitated standardized workflows, reducing process variability and improving synchronization between human and robotic elements. The results showed a significant increase in productivity, with task completion times reduced by 25%, primarily due to the improved organization and flow achieved through 5S. Efficiency gains were observed through consistent task performance enabled by SAB, while the error rate decreased by 40% due to Poka Yoke’s error-proofing mechanisms. These findings highlight the potential of Lean methods to enhance the effectiveness of human-robot collaboration by addressing inefficiencies, standardizing workflows, and reducing errors. This study underscores the value of integrating Lean principles into hybrid work environments to optimize performance and quality in industrial applications.