Intelligent Poka Yoke System for Secure and Efficient Industrial Equipment Monitoring and Control

Ensuring the safety and efficiency of manufacturing processes is required in Industry 4.0. To address this, an intelligent Poka Yoke system is proposed, specifically designed for monitoring and controlling Industry Programmable Logic Controller machines. This system prioritizes security by requiring strict staff authorization, providing timely alerts, and granting access privileges based on predetermined criteria. It efficiently prevents unauthorized access and minimizes potential industrial dangers by leveraging modern technology such as employee access keys and NFC authentication. NFC is used to authenticate employee credentials, allowing access to only approved jobs by using Raspberry Pi Pico as a controller. The technology detects anomalies and safety threats in real time while continuously monitoring equipment operations. The generated data is virtualized in a user-friendly web application, conveniently stored in Mongo dB cloud, allowing for instant notifications and automated equipment shutdown when necessary. This system improves workplace security, safety, and efficiency by streamlining operations and increasing productivity.