Effectivity of quality methods used on the shop floor of a serial production – how important is Poka Yoke?

There are a lot of different quality methods available to optimise shop floor processes. Besides the difficulty of choosing the right method, the estimation of the effectiveness of these methods remains uncertain. To date, a scientific analysis of a shop floor in series production via a business simulation and the selected optimisation methods does not exist. A model with a business simulation that helps assess the usage of the quality methods on the shop floor was developed. Therefore, the objective of this scientific study is to close the research gap with a systematic analysis of series production with a business simulation and the generated data using the design of experiments (DoE). This combination is new for research. The selection of the methods used in this business simulation is based on different studies. Methods used are 5S, Poka Yoke, Kanban and Standard Work Sheet. As KPIs, the rework, the lead time and adherence to delivery dates are measured. The developed simulation game on the shop floor with the results enables optimisation experts in companies to identify the optimal quality method or combination. This allows a first approach before a real test can take place.