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

By Mohammed Hamed Ahmed Soliman

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.

• Format: Paperback
• Language: English
• ISBN: B0GKWFY4LR
• ISBN13: 9798262529711
• Release Date: January 2026
• Publisher: Independently Published
• Length: 80 Pages
• Weight: 0.20 lbs.
• Dimensions: 0.2" x 5.3" x 8.0"