AI-Powered Poka Yoke
Modern Methods for Mistake-Proofing and Quality Control in Lean Manufacturing
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AI-Powered Poka Yoke
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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.