{"id":6874,"date":"2026-02-01T04:39:00","date_gmt":"2026-02-01T04:39:00","guid":{"rendered":"https:\/\/sciil.com\/case-study\/digital-poka-yoke-verification-with-sciil-pyv-success-story\/"},"modified":"2026-03-12T16:57:27","modified_gmt":"2026-03-12T16:57:27","slug":"digital-poka-yoke-verification-with-sciil-pyv-success-story","status":"publish","type":"case-study","link":"https:\/\/sciil.com\/en\/case-study\/digital-poka-yoke-verification-with-sciil-pyv-success-story\/","title":{"rendered":"Digital Poka Yoke Verification with SCIIL PYV Success Story"},"content":{"rendered":"\n<p data-wp-context---core-fit-text=\"core\/fit-text::{&quot;fontSize&quot;:&quot;&quot;}\" data-wp-init---core-fit-text=\"core\/fit-text::callbacks.init\" data-wp-interactive data-wp-style--font-size=\"core\/fit-text::context.fontSize\" class=\"has-fit-text\">SCIIL ePYV does not replace poka-yoke devices or methods, but digitizes their planning, execution, monitoring and documentation.<\/p>\n\n<p>Case study: Digital poka-yoke verification replaces paper-based checks and creates measurable benefits.<\/p>\n\n<p>At a <strong>Customer Experts Workshop in 2017<\/strong>, key users of the SCIIL system expressed a clear desire for an IT-supported solution. The aim was to digitize the planning, execution, monitoring and documentation of poka-yoke inspections, as paper-based shift books, manual overviews and time-consuming documentation were increasingly no longer meeting the requirements of series production.<\/p>\n\n<figure class=\"wp-block-image size-full\"><img fetchpriority=\"high\" decoding=\"async\" width=\"894\" height=\"504\" src=\"https:\/\/sciil.com\/wp-content\/uploads\/2020\/03\/image-1.png\" alt=\"\" class=\"wp-image-6846\" srcset=\"https:\/\/sciil.com\/wp-content\/uploads\/2020\/03\/image-1.png 894w, https:\/\/sciil.com\/wp-content\/uploads\/2020\/03\/image-1-300x169.png 300w, https:\/\/sciil.com\/wp-content\/uploads\/2020\/03\/image-1-768x433.png 768w\" sizes=\"(max-width: 894px) 100vw, 894px\" \/><\/figure>\n\n<h2 class=\"wp-block-heading\" id=\"h-ausgangssituation-papierbasierte-poka-yoke-verifikation\">Initial situation: Paper-based poka-yoke verification  <\/h2>\n\n<p>Poka-yoke verification was paper-based using <strong>shift books, printed inspection instructions and weekly overviews<\/strong>. At the same time, manually created reports and overviews existed, meaning that a centralized and up-to-date view of the status of the poka-yoke tests on a PY dashboard was not possible at all times.<\/p>\n\n<figure class=\"wp-block-image size-large\"><img decoding=\"async\" width=\"1024\" height=\"407\" src=\"https:\/\/sciil.com\/wp-content\/uploads\/2020\/03\/Poka-Yoke-Paperbased-1024x407.png\" alt=\"Paperbased Poka Yoke\" class=\"wp-image-6844\" srcset=\"https:\/\/sciil.com\/wp-content\/uploads\/2020\/03\/Poka-Yoke-Paperbased-1024x407.png 1024w, https:\/\/sciil.com\/wp-content\/uploads\/2020\/03\/Poka-Yoke-Paperbased-300x119.png 300w, https:\/\/sciil.com\/wp-content\/uploads\/2020\/03\/Poka-Yoke-Paperbased-768x305.png 768w, https:\/\/sciil.com\/wp-content\/uploads\/2020\/03\/Poka-Yoke-Paperbased-1536x610.png 1536w, https:\/\/sciil.com\/wp-content\/uploads\/2020\/03\/Poka-Yoke-Paperbased.png 1908w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n<p>Paper-based poka-yoke verification had several key disadvantages:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>No timely monitoring of implementation<\/li>\n\n\n\n<li>No immediate reaction  <\/li>\n\n\n\n<li>Documentation through filing<\/li>\n\n\n\n<li>Mauelle reporting<\/li>\n\n\n\n<li>No &#8220;lessons learned&#8221;  <\/li>\n\n\n\n<li>Laborious OEM and customer audits  <\/li>\n<\/ul>\n\n<p>From the experts&#8217; point of view, it was therefore clear that the paper-based control was ineffective and unreliable. As a result, there was a need for an electronic solution to manage and monitor poka-yoke activities.<\/p>\n\n<h2 class=\"wp-block-heading\" id=\"h-anforderungen-aus-dem-kundenworkshop\">Requirements from the customer workshop:  <\/h2>\n\n<p>Specific requirements for software to monitor poka-yoke activities were defined during a customer workshop:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Mobile and<strong>simple input<\/strong><\/li>\n\n\n\n<li>Real-time control at line level<\/li>\n\n\n\n<li>Automated workflows and notifications<\/li>\n\n\n\n<li>PY Dashboards<\/li>\n<\/ul>\n\n<div class=\"wp-block-cover\"><img decoding=\"async\" width=\"787\" height=\"786\" class=\"wp-block-cover__image-background wp-image-6845\" alt=\"\" src=\"https:\/\/sciil.com\/wp-content\/uploads\/2020\/03\/image.png\" data-object-fit=\"cover\" srcset=\"https:\/\/sciil.com\/wp-content\/uploads\/2020\/03\/image.png 787w, https:\/\/sciil.com\/wp-content\/uploads\/2020\/03\/image-300x300.png 300w, https:\/\/sciil.com\/wp-content\/uploads\/2020\/03\/image-150x150.png 150w, https:\/\/sciil.com\/wp-content\/uploads\/2020\/03\/image-768x767.png 768w\" sizes=\"(max-width: 787px) 100vw, 787px\" \/><span aria-hidden=\"true\" class=\"wp-block-cover__background has-background-dim\"><\/span><div class=\"wp-block-cover__inner-container is-layout-flow wp-block-cover-is-layout-flow\">\n<ul class=\"wp-block-list\">\n<li><\/li>\n<\/ul>\n<\/div><\/div>\n\n<ul class=\"wp-block-list\"><\/ul>\n\n<p>Based on these requirements, SCIIL developed the ePYV &#8211; Poka Yoke Verification module.<\/p>\n\n<h2 class=\"wp-block-heading\" id=\"h-losung-digitale-poka-yoke-verifikation-mit-sciil-epyv\">Solution: Digital poka-yoke verification with SCIIL ePYV<\/h2>\n\n<h3 class=\"wp-block-heading\" id=\"h-reduzierung-laufender-aufwande-durch-digitalisierung\">Reduction of ongoing expenses through digitization<\/h3>\n\n<p><strong>Assessment basis<\/strong>: Automotive plant with <strong>2-shift operation<\/strong>, around <strong>100 poka-yoke tests per production day<\/strong> and around <strong>260 production days per year<\/strong>. This scenario corresponds to the typical use of poka-yoke tests in series production and forms the basis for the following benefit analysis.<\/p>\n\n<p><strong>Measurement method (customer-based)<\/strong>: Time measurements before and after implementation for the entire accompanying process: planning of checks, maintenance and distribution of instructions, manual documentation, data follow-up for overviews and boards as well as the provision of evidence for internal and external audits.  <\/p>\n\n<p><strong>Result: <\/strong>Thanks to digital poka-yoke verification, the customer was able to permanently reduce ongoing expenses. The measured reduction in workload is around <strong>200 hours per year<\/strong> and is divided between production, quality and back office.<\/p>\n\n<p>This time saving results from the elimination of paper-based activities, the centralized digital planning and maintenance of poka-yoke checks, automated status tracking and the immediate availability of all evidence in the system. Instead of manual coordination and rework, clearly structured, digital processes are created.<\/p>\n\n<h2 class=\"wp-block-heading\" id=\"h-business-case-amp-entscheidung-des-kunden\"><strong>Business case &amp; decision of the customer<\/strong>:  <\/h2>\n\n<p>Based on these results, the global management approved the <strong>rollout of SCIIL PYV to 73 plants worldwide<\/strong>.<br\/><\/p>\n","protected":false},"excerpt":{"rendered":"<p>SCIIL ePYV does not replace poka-yoke devices or methods, but digitizes their planning, execution, monitoring and documentation. Case study: Digital poka-yoke verification replaces paper-based checks and creates measurable benefits. At a Customer Experts Workshop in 2017, key users of the SCIIL system expressed a clear desire for an IT-supported solution. The aim was to digitize [&hellip;]<\/p>\n","protected":false},"featured_media":6875,"parent":0,"template":"","case-category":[186,191],"case-tag":[512],"class_list":["post-6874","case-study","type-case-study","status-publish","has-post-thumbnail","hentry","case-category-mobile-audits","case-category-production-digitalization","case-tag-poka-yoke-software"],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v25.1 (Yoast SEO v27.1.1) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Digital poka-yoke verification vs. paper-based control<\/title>\n<meta name=\"description\" content=\"Case study on digital poka-yoke verification with SCIIL software: planning, monitoring and documentation. 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