VIRTA-Yoke: A Virtual-Integrated Poka-Yoke System for Error Prevention and Operator Training in Manufacturing Processes

Guillermo Leale, Guillermo Leale, Baltazar Cortina, Rodrigo D’Andrea

2025

Abstract

This paper introduces VIRTA-Yoke (VIRTA: Virtual Integrated Reliability and Training Assistant), a proof-of-concept virtual Poka-Yoke platform developed to increase reliability and efficiency in manufacturing processes for aluminum engine components. In contrast to traditional mechanical Poka-Yoke systems that require custom fixtures for each part, VIRTA-Yoke employs a low-cost webcam and a virtual reality (VR) headset to guide operators through each assembly step, verify correct placement in specific control areas, and provide real-time feedback when deviations occur. The system uses a convolutional neural network (ConvNet) to detect errors in coil insert placements. This information appears on the VR headset, minimizing operator distraction, optimizing operation times, and improving process adherence. In addition, the VR headset serves as a training environment, allowing new personnel to learn assembly procedures through a virtual component model before working on the factory facility. Preliminary tests indicate an accuracy exceeding 90% in overall defect detection, suggesting that VIRTA-Yoke is a scalable, cost-effective method for streamlining quality control, improving operator training, and eliminating the need for multiple custom mechanical fixtures across a wide range of parts.

Paper Citation

in Harvard Style

Leale G., Cortina B. and D’Andrea R. (2025). VIRTA-Yoke: A Virtual-Integrated Poka-Yoke System for Error Prevention and Operator Training in Manufacturing Processes. In Proceedings of the 20th International Joint Conference on Computer Vision, Imaging and Computer Graphics Theory and Applications - Volume 1: GRAPP; ISBN 978-989-758-728-3, SciTePress, pages 421-428. DOI: 10.5220/0013381100003912

in Bibtex Style

@conference{grapp25,
author={Guillermo Leale and Baltazar Cortina and Rodrigo D’Andrea},
title={VIRTA-Yoke: A Virtual-Integrated Poka-Yoke System for Error Prevention and Operator Training in Manufacturing Processes},
booktitle={Proceedings of the 20th International Joint Conference on Computer Vision, Imaging and Computer Graphics Theory and Applications - Volume 1: GRAPP},
year={2025},
pages={421-428},
publisher={SciTePress},
organization={INSTICC},
doi={10.5220/0013381100003912},
isbn={978-989-758-728-3},
}

in EndNote Style

TY - CONF

JO - Proceedings of the 20th International Joint Conference on Computer Vision, Imaging and Computer Graphics Theory and Applications - Volume 1: GRAPP
TI - VIRTA-Yoke: A Virtual-Integrated Poka-Yoke System for Error Prevention and Operator Training in Manufacturing Processes
SN - 978-989-758-728-3
AU - Leale G.
AU - Cortina B.
AU - D’Andrea R.
PY - 2025
SP - 421
EP - 428
DO - 10.5220/0013381100003912
PB - SciTePress