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Programming Mat-Poka-yoke system control effect of unsteady convection-diffusion behavior for plastic manufacturing
Ahmed M Abed1, Ali AlArjani1, Laila F Seddek2
1Department of Industrial Engineering, College of Engineering, Prince Sattam bin Abdulaziz University, Al-Kharj, Saudi Arabia.
Plos One
|April 8, 2026
Summary
A novel dual digital poka-yoke simulator enhances plastic manufacturing by accurately modeling convection-diffusion. This system improves process control and product quality, significantly reducing defects.
Area of Science:
- Materials Science
- Chemical Engineering
- Computational Science
Background:
- Plastic manufacturing defects arise from inaccurate thermal convection and diffusion control.
- Existing methods lack precision in modeling unsteady convection-diffusion processes.
Purpose of the Study:
- To develop a dual digital poka-yoke simulator for precise modeling of unsteady convection-diffusion.
- To improve defect prediction and control in plastic manufacturing stages like blowing and drying.
Main Methods:
- Mathematical formulation of unsteady convection-diffusion using discrete singular convolution transformer.
- Implementation of Runge-Kutta 4th order and SSP-RK54 schemes within the Mat-Poka-Yoke system (Mat-PYS).
- Validation through convergence rate, absolute error, L2 error, and L∞ error analysis.
Main Results:
- The Mat-PYS demonstrated high accuracy and efficiency in solving convection-diffusion equations.
- Parametric analysis confirmed the mechanism's ability to resist defect generation.
- Overall Equipment Effectiveness (OEE) improved from 76.6% to 88.9%.
Conclusions:
- The proposed dual digital poka-yoke simulator effectively addresses defects in plastic manufacturing.
- The system offers precision, efficiency, and applicability for complex convection-diffusion problems.
- Product quality significantly improved to a 5.2 sigma level.
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