Programming Mat-Poka-yoke system control effect of unsteady convection-diffusion behavior for plastic manufacturing mathematically

Ahmed M Abed, Ali AlArjani, Laila F Seddek, Mohamed Salah, Ola Ragb and Rania B M Amer

PLOS ONE, 2026, vol. 21, issue 4, 1-36

Abstract: The blowing and drying stages in the plastic manufacturing process generate many defects due to a lack of accuracy in estimating thermal convection and its diffusion control. Therefore, dual digital poka-yoke simulator phases have been built to describe the unsteady state of convection-diffusion mathematically (i.e., parabolic behavior), and converted to ordinary type using a discrete singular convolution transformer. The numerical solution improves the mechanism of JRNS (Jidoka recruit’s network system) to be easily programmed to be highly controlled. The mathematical poka-yoke simulator formulation relies on Runge-Kutta 4th order and five-stage fourth-order robust stability protective Runge-Kutta (SSP-RK54) schemes as discussed in 1st phase and called Mat-Poka-Yoke system (Mat-PYS) alternating between three stages. The accuracy of the Mat-PYS has been tested via measuring the rate of convergence, the absolute error, the L2 error, and the L∞ error, with errors up to 1×10−5. The obtained outcomes are described both in tabular and graphical form, which almost includes the validity of these mechanisms to hold on to the precision, efficiency, simplicity, and applicability for solving convection-diffusion equations. The applicability emphasized via parametric analysis to debate the effect of convective velocities, diffusion coefficients, and time at different locations on results to resist the defect causes generation as demonstrated in 2nd phase. The OEE for plastic injection machine process has been improved from 76.6% to 88.9% when controlled by proposed mechanism, and products quality improved to 5.2 sigma level.

Date: 2026
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Persistent link: https://EconPapers.repec.org/RePEc:plo:pone00:0336617

DOI: 10.1371/journal.pone.0336617

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