Model based on Poka Yoke 4.0 and Predictive Maintenance with IoT to increase efficiency in rolling extinguishers

In recent years, the growing demand for fire safety equipment, such as extinguishers, has positioned metalworking companies as key contributors to the Peruvian manufacturing sector. However, many still face critical deficiencies in their production processes, mainly due to welding defects, assembly errors, and failures in the cutting machine. To address this, the study proposes a technological improvement model that integrates Poka Yoke 4.0 to prevent errors and Predictive Maintenance with IoT to anticipate mechanical and control system failures. After implementation, the defective product rate (DP) in extinguishers was reduced to 4.5%, cutting machine availability increased to 91.3%, and its overall equipment effectiveness (OEE) reached 86.4%, reflecting an improvement in operational efficiency above 87.5%. These results demonstrate the model's effectiveness in reducing rework and downtime, and its potential for replication in SMEs in the metal-mechanic sector.