Lean-AI: A Humanistic Integration of Lean and AI

by Adil Dalal, Elizabeth A. Cudney

Overview

We stand at the threshold of a transformative era where the convergence of Lean methodologies and artificial intelligence (AI) is redefining operational excellence. This book is a pioneering exploration of this integration, offering a roadmap for organizations seeking to harness AI’s potential while preserving the human-centric values at the heart of Lean. It provides a deep dive into how Lean principles – focused on efficiency, waste reduction, and continuous improvement – can be enhanced through AI-driven intelligence, agility, and innovation. More than just a technical guide, this book is an invitation to rethink the future of work, leadership, and culture in an AI-powered world.

Lean-AI: A Humanistic Integration of Lean and AI empowers readers with the tools and insights necessary to navigate the evolving landscape of Industry 5.0+. Through real-world case studies, practical strategies, and in-depth discussions, this book illustrates how organizations can leverage AI to accelerate Lean transformation, enhance human performance, and drive sustainable growth. Readers will gain actionable knowledge on integrating AI with Lean tools such as 5S, poka-yoke, single minute exchange of dies, total productive maintenance, and value stream mapping, among others. The book also highlights the critical role of leadership and culture in ensuring AI-driven Lean implementations uplift rather than replace human capabilities.

This book is designed for forward-thinking innovators, business leaders, Lean practitioners, and AI enthusiasts eager to explore the synergy between technology and human-centric process improvement. Whether you are an executive driving digital transformation, a Lean expert looking to modernize methodologies, or a professional seeking to understand AI’s role in operational excellence, this book provides a strategic guide to mastering Lean-AI integration. It is an essential read for those ready to challenge conventional paradigms and embrace the future of efficiency, collaboration, and intelligent innovation.

Product Details

ISBN-13:	9781032875033
Publisher:	CRC Press
Publication date:	09/16/2025
Series:	Continuous Improvement Series
Pages:	264
Product dimensions:	6.12(w) x 9.19(h) x (d)

About the Author

Adil Dalal is the President and CEO of Pinnacle Process Solutions, Intl, LLC, holding two master’s degrees and a doctorate in business administration and several certifications in leadership, coaching, quality, Lean, Six Sigma, project management, and digital transformations. A visionary leader with 20+ years of global experience, he has driven 350+ enterprise-wide transformations across 25 industries and five continents, spanning Lean Six Sigma, digital transformation, leadership, software development, factory re-layouts, and mergers and acquisitions. A strategic coach to executives and government leaders, Dr. Dalal enhances human potential and return on investment through leadership excellence. Named a Top 15 Entrepreneur Disrupting Their Industry by MSN, he serves on the Forbes Executive Coaching Council and is a Platinum CEO Life Member. A dynamic keynote speaker, he has delivered 100+ talks worldwide, including TEDx Brussels, the Saudi Government’s Quality Conference, and the UK House of Lords. His book The 12 Pillars of Project Excellence has won the ASQ Crosby Zero-Defect Medal, the Shingo Research Award, and the Axiom Best Business Book Award. Other accolades include the Global Award for Outstanding Contribution to Quality and Leadership, Most Inspiring Thought Leader 2024, and Excellence in Teaching. A pioneer of Sensei Leadership, iLean Technology, iCulture, The V-Factor, and Pinnacle Performance Zone, Dr. Dalal is a catalyst for high-performance teams, revolutionizing leadership, teamwork, and personal development.

Elizabeth A. Cudney, PhD, is President of Cudney Consulting Group, LLC, and a Professor of data analytics at the John E. Simon School of Business at Maryville University. She earned a BS in industrial engineering at North Carolina State University, a master’s in mechanical engineering and an MBA at the University of Hartford, and a PhD in engineering management at the University of Missouri–Rolla. Dr. Cudney received the 2025 ASQ Grant Medal for exemplary leadership in designing and delivering curriculum. She received the 2024 Book of the Year Award from the International Lean Six Sigma Institute and the 2023 Walter E. Masing Book Prize from the International Academy for Quality for her book Lean Sustainability: A Pathway to a Circular Economy. Dr. Cudney received the 2022 Crosby Medal from ASQ for her book The Ten Commandments of Lean Six Sigma. She also received the 2021 Bernard R. Sarchet Award from ASEE EMD for lifetime achievement in engineering management education. She received the 2021 Walter E. Masing Book Prize from the International Academy for Quality for her book The Ten Commandments of Lean Six Sigma. In 2018, Dr. Cudney received the ASQ Crosby Medal for her book Design for Six Sigma: A Practical Approach through Innovation. She received the 2018 IISE Fellow Award. She also received the 2017 Yoshio Kondo Academic Research Prize from the International Academy for Quality for sustained performance in exceptional published works. In 2014, Dr. Cudney was elected as an ASEM Fellow. In 2013, she was elected as an ASQ Fellow. In 2010, Dr. Cudney was inducted into the International Academy for Quality. She received the 2008 ASQ A.V. Feigenbaum Medal and the 2006 SME Outstanding Young Manufacturing Engineering Award. She has published 15 books and over 135 peer-reviewed journal papers. Dr. Cudney is a certified Lean Six Sigma Master Black Belt. She holds eight ASQ certifications, which include ASQ Certified Quality Engineer, Manager of Quality/Operational Excellence, and Certified Six Sigma Black Belt, among others.

Table of Contents

1. Lean Landscape. 2. The Emergence of AI and Existing and Future Applications. 3. The Importance of the Shingo Model to the Human Side of Lean. 4. Integrating Lean Tools with AI. 5. 6S-AI: 5S Overview. 6. VSM-AI. 7. Poka-Yoke-AI: Overview of Tool. 8. SMED-AI. 9. TPM-AI. 10. Material Management-AI. 11. Hoshin Kanri-AI. 12. Lean Office-AI. 13. Kaizen and Kaikaku-AI. 14. Mixed Model Line Design-AI. 15. Lean-AI Case Studies. 16. Guidelines to Lean Practitioners to Adapt to the Future of Lean 5.0+: The Evolution of Industrial Revolutions. 17. How the AI Revolution Will Transform the Corporate Ecosystems of the Future. 18. The Detrimental Effects of AI on Learning, Decision-Making, and Cognitive Functions among Corporate Employees: Impacts on Learning and Skill Development.