Industry 4.0 Based Poka-Yoke Store Management System

Modern warehouses and retail stores often struggle to complete customer orders quickly, especially when newly joined employees are not familiar with where products are located.Traditional manual order-picking methods usually involve searching through racks, which can cause mistakes, slow down the process, and reduce overall productivity.To address this issue, this paper presents the design and development of a Smart LED Guided Order Picking System for efficient store management.In the proposed system, each incoming order is identified using a QR code.Once the QR code is scanned, LED lights installed on the corresponding product trays or racks automatically turn ON, clearly showing the worker where the required items are placed.The LED remains ON until the correct quantity of the product is picked.A microcontroller-based control unit handles communication between the QR scanner, database, and LED modules.This system makes the picking process simple and intuitive, even for new employees, thereby reducing the need for extensive training.It also helps in completing orders faster and with higher accuracy.Experimental results indicate that the proposed system greatly improves order fulfilment speed and significantly reduces picking errors when compared to conventional methods.The solution is low-cost, scalable, and well suited for small and medium-sized warehouses and retail environments.