0%

Digital Work Instruction and Poke-Yoke

Turn complex work instructions into error - proof digital guidance

Our AI system replaces manual quality checks with step-by-step digitized SOPs, and  andon-like alerts to prevent mistakes - ensuring perfect execution of critical assembly sequences.

Trusted by industry-leaders for DIGITAL POKE YOKE SOLUTIONS

THE PROBLEM

Manual quality control is hurting your reputation and bottom line

High Defect Escape Rates

Lead to customer complaints and costly product recalls

High Defect Escape Rates

Lead to customer complaints and costly product recalls

High Defect Escape Rates

Lead to customer complaints and costly product recalls

High Defect Escape Rates

Lead to customer complaints and costly product recalls

THE PROBLEM

Manual quality checks undermine error-proof assembly

Missed Assembly Steps

Lead to high COPQ and field failures

Hidden Issues Surface Too Late

Causing unexpected field defects and reputational damage

No Assembly Sequence Checks

Errors in 'sandwich' assemblies go undetected, causing costly defects

Dependent on Skilled Labour

Extends lead times & causes inconsistent worker outputs

The Solution

Ensure perfect process compliance with AI monitoring

Our Intelligent Process Optimization system, Nagare™, combines digital SOPs with real-time process verification to prevent assembly errors while protecting workers’ privacy.

Learn more about Nagare

Display step-by-step SOPs digitally
Track completed activities automatically
Configure multiple assembly variants
Generate bar codes for assembly lines
Ensure proper sequence compliance

Zero

assembly errors

100%

process compliance

Monitor assembly actions in real-time
Identify errors before they progress
Eliminate post-assembly testing costs
Enable immediate error correction
Track critical component assembly

$140k

savings in inspection and COPQ

High

FMEA effectiveness 
score

Cycle-level video traceability for data-driven Kaizen initiatives
Identify and fix bottlenecks with Time and Motion Studies
Reduce supervision costs with intelligent monitoring
Ensure process adherence and worker safety monitoring

25%

higher productivity

30%

reduction in downtime

Digitize Work Instructions

Display step-by-step SOPs digitally
Track completed activities automatically
Configure multiple assembly variants
Generate bar codes for assembly lines
Ensure proper sequence compliance

Zero

assembly errors

100%

process compliance

Prevent Defect Escapes

Monitor assembly actions in real-time
Identify errors before they progress
Eliminate post-assembly testing costs
Enable immediate error correction
Track critical component assembly

$140k

savings in inspection and COPQ

High

FMEA effectiveness  score

Eliminate Time Waste & Maximize Yield

Cycle-level video traceability for data-driven Kaizen initiatives
Identify and fix bottlenecks with Time and Motion Studies
Reduce supervision costs with intelligent monitoring
Ensure process adherence and worker safety monitoring

25%

higher productivity

30%

reduction in downtime

customer success

See digital work instruction and poke-yoke in action

Discover how industry leaders put intelligent process guidance to work with Jidoka’s AI vision systems.

How Maruti Suzuki Automated and Scaled Engine Bore Inspections with Jidoka

Automotive

Engine Tappet inspection with AI vision and HURON hardware

Detects 10+ critical defects with >99% accuracy
Processes 200+ images/500 MB per part in 6 seconds
Identifies subjective defects like linemark, chatter mark unclean and more…

Read case study

How Britannia Automated In-line Inspection for Biscuits with Jidoka

FMCG

High-speed biscuit inspection with automated quality control:

Near 100% accuracy at 12,000+ biscuits per minute
Precise automated rejection of defective biscuits
Retrofitted into existing production lines

Read case study

How Diageo Achieved In-Process Labeling Precision with Jidoka

Manufacturing

Labelled bottle inspection with AI vision system and modular hardware:

Complete Label inspection automation at 300+ bottles/minute
Ensures accurate text, orientation, and label quality
Automates end-of-line quality control and consistent standards

Read case study

CONNECT WITH OUR EXPERTS

Discover how Jidoka can help you reduce costs & improve efficiency.