Poka Yoke software such as SCIIL PYV digitizes Poka Yoke verification, monitors Poka Yoke activities and replaces the paper-based PY checklist with an electronic Poka Yoke check with clear instructions.
PY checklist, mobile input, digital real-time control
Why digital Poka Yoke verification with software is indispensable today
Poka-yoke inspections are not optional. Companies must carry them out regularly, completely and verifiably – often several times per shift. In practice, paper-based checks quickly reach their limits.
- Audits are carried out late or not at all
- Reactions to NOK results are too late because superiors are also informed too late
- At the same time, there is a lack of reliable evidence for OEM and customer audits.
SCIIL PYV (Poka Yoke Verification) completely digitizes this critical process: electronic Poka Yoke verification actively prevents errors, significantly shortens response times and creates a reliable basis for audit security.
Digital Poka Yoke software: real-time control instead of late audit response
SCIIL PYV gives those responsible an up-to-date overview of the status of all poka-yoke tests at all times. The system shows in real time whether tests have been carried out, whether they were completed on time and whether they were completed with an OK or NOK.
If a check fails or the system reports an NOK, SCIIL PYV automatically informs the responsible supervisors. As a result, process reliability is no longer based on manual records in shift books or lists maintained at a later date, but on up-to-date and reliable data.
The result for the customer is significantly shorter response times, lower quality risks and clearly defined responsibilities directly on the store floor.
Technically prevent errors instead of just documenting them
SCIIL PYV goes far beyond classic checklists:
If a poka-yoke check is not carried out within the defined time, the system automatically blocks the catch-up.
In the event of an NOK result, SCIIL PYV blocks the station concerned until a confirmed OK check has been carried out.
Digital PY boards show open or NOK PPY tests and locked stations without a time delay
In this way, the system ensures that errors are not passed on unnoticed. Quality is ensured technically instead of organizationally.
Mobile Poka Yoke checklist: easy input on mobile devices
In practice, poka-yoke checks rarely fail due to a lack of commitment on the part of employees. Frequent causes are unclear instructions or complex forms, while at the same time there is high time pressure on the line.
SCIIL PYV guides employees step by step through each test and the stored instructions make it easier to carry out. Mandatory confirmation of individual test steps with a simple decision between OK and NOK is therefore simple and clear.
The input is optimized for mobile devices and works on iOS, Android and Windows devices. This reduces the amount of training required, increases inspection quality and minimizes operating errors – even for less experienced employees.
Planning and control: digital control instead of gut feeling
With SCIIL PYV, companies can reliably plan and easily control poka-yoke tests because the PY schedule is created automatically. Test intervals can be flexibly defined per shift, daily, weekly or monthly. At the same time, clearly defined roles and user rights ensure that planning, execution and monitoring are clearly separated from each other.
This eliminates the need for additional Excel lists and paper forms, leaving no room for human error.
Digital Poka Yoke real-time board for maximum transparency
The electronic poka-yoke board completely replaces traditional whiteboards and shift books. It shows the current status of all tests and also marks overdue poka yokes and blocked stations.
The board is online at all times, providing managers with an objective basis for decision-making in real time – without queries and without delays.
Poka Yoke audit proof through complete digital documentation
SCIIL Poka Yoke Software documents every Poka Yoke test in a complete and audit-proof manner, making the documentation complete and traceable:
- who carried out which test
- when the test was carried out
- which result was available (OK / NOK)
- which reaction was triggered
- when a lock was lifted
This seamless traceability is therefore a clear advantage for OEM, customer and system audits. According to the case study, it was one of the main reasons for the global rollout of SCIIL PYV at 73 plants for one customer.
The added value of the SCIIL PYV Poka Yoke software at a glance
SCIIL PYV significantly reduces response times in the event of missing or incorrect checks, enforces quality technically instead of documenting it on paper and facilitates implementation for employees. The module provides managers with complete real-time transparency and audit-proof documentation and reduces the planning and control effort in day-to-day business.
