AI-Powered Poka Yoke

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 Soliman—Lean expert, executive advisor, and author of over 10 publications—bridges the classic Toyota Production System philosophy with today's digital manufacturing tools. You'll discover how to 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: The fundamentals of poka yoke and its evolution from Shingo's era to Industry 4.0. Step-by-step implementation roadmap with checklists. How to combine traditional error-proofing with AI-enhanced systems. Real case studies from automotive, electronics, and pharmaceuticals. Practical dashboards and KPIs to measure effectiveness. Strategies to build a zero-defect culture. Perfect for Lean manager, manufacturing engineer, and quality leaders. This book gives you tools to reduce defects, and build error-proof factories of the future.