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AI-Powered Poka Yoke: Modern Methods for Mistake-Proofing and Quality Control in Lean Manufacturing
Paperback
Series: Lean Foundations & Advanced AI Applications
Technology & EngineeringGeneral Computers
Publisher: Independently Published
Published: Jan 31 2026
Pages: 80
Weight: 0.20
Height: 0.17 Width: 5.25 Depth: 8.00
Language: English
Error-proofing is no longer just about simple jigs and sensors. In the era of Industry 4.0, factories demand smarter, AI-powered approaches to achieve zero defects at the source.
In this practical guide, Professor Mohammed Hamed Ahmed Soliman-Lean expert, executive advisor, and author of over 100 publications-bridges the classic Toyota Production System philosophy with today's digital manufacturing tools.
You'll discover how to design and implement poka yoke systems that are:
- Simple and reliable - grounded in Toyota's principles.
- Smart and predictive - powered by AI, vision systems, and digital twins.
- Scalable and sustainable - embedded into continuous improvement culture.
Inside you'll learn:
- The fundamentals of poka yoke and its evolution from Shingo's era to Industry 4.0.
- Step-by-step implementation roadmap with checklists and templates.
- How to combine traditional error-proofing with AI-enhanced systems.
- Real-world case studies from automotive, electronics, and pharmaceuticals.
- Practical dashboards and KPIs to measure effectiveness.
- Strategies to build a zero-defect culture that engages both people and machines.
Whether you are a Lean manager, manufacturing engineer, or quality leader, this book gives you actionable tools to reduce defects, cut costs, and build error-proof factories of the future.
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