The Connected Worker Platform Built for Zero-Defect Automotive Manufacturing
Poka gives your automotive frontline the tools to execute PFMEA-aligned standard work to standard, at scale, across every line and plant you run. So a missed step doesn't become an escaped defect, a charge-back, or a line down call.
Trusted by Top Maunfacturers
The Top Challenges Automotive Manufacturers Face Today
Automotive smart manufacturing leaves little room for error. OEM quality standards are strict. Workforces are retraining for electrification. Critical information falls through the cracks between shifts.
Zero-defect quality and OEM traceability
OEM scorecards measure Tier 1 and Tier 2 suppliers on PPM defect rates and IATF 16949 audit performance. Operators must get every torque, weld, and assembly step right and document it, on every unit. When a quality issue comes up, you need to trace it back fast: to the operator, shift, and process step. On paper, one escape can become a containment, a charge-back, or a delisting.
Rapid retraining for the EV transition
Production lines are shifting toward EV components and new vehicle architectures. Workers need retraining fast, and at scale, without slowing output. Paper SOPs and classroom training can't keep pace with how fast the work changes.
Inconsistent execution and process discipline
Standard work has to hold across every shift, operator, and program, or PPM drifts. Layered process audits, control-plan checks, and changeover validations need to happen on schedule, with the right people signing off. Tribal procedure variants hide defects in the gaps.
Skills gap and knowledge transfer risk
Die makers, tool-and-die experts, controls technicians, and electrified-powertrain specialists are retiring. Their know-how is hard to replace. If you don't capture it, new technicians start from scratch, and old mistakes repeat.
Help Your Automotive Frontline Make Zero-Defect Execution Everyday Practice
Poka is a connected worker platform for complex, high-precision manufacturing, including automotive manufacturing and suppliers. It brings standard work, control plans, audits, training, and data into one system.Every operator, technician, and supervisor can use it.
Zero-defect quality and traceability
Operators complete and log every torque, weld, and control-plan check to the PFMEA, on every unit. Trace any concern to the operator, shift, and step in seconds. Poka customers see 58% fewer quality disruptions and stay IATF audit-ready.
Faster issue resolution and JIS reliability
Structured issue capture and automated escalation keep lines moving. Bosch Automotive cut issue management time 60%, improved Mean Time Between Repair 54%, and saved 200,000 euros a year.
Rapid retraining for new and EV programs
Industrial AI turns legacy PFMEAs, control plans, and training into instructions up to 77% faster. New standard work deploys to every line instantly. You retrain at market speed..
Skilled-trades knowledge, captured
Poka captures die-maker, tool-and-die, and controls-technician expertise as digital troubleshooting guides before it retires. It tracks competency in real time. Customers retain workers 38% longer.
Process discipline across every shift
Layered process audits, changeover validations, and gauge checks happen on schedule, with proper sign-off. PPM stops drifting between shifts and programs.
Measurable productivity gains
Bosch reported +8% direct productivity after deploying Poka. Customers see +24% productivity on average.
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Poka Capabilities That Matter Most for Automotive Manufacturers and Suppliers
Poka is a single, unified platform where each capability reinforces the others, building a culture of continuous improvement.
OEM scorecards demand zero defects and IATF-grade traceability. Poka moves layered process audits, control-plan checks, gauge R&Rs, changeover validations, and 5 Whys onto the line, with sign-offs. That gives you an audit trail, ready in seconds for any SQA or IATF assessor. Automotive customers see 58% fewer quality disruptions.
58% fewer quality disruptions | IATF and customer audit-ready
Tribal procedure variants are where defects hide. Poka's work instruction software for automotive manufacturing replaces them with digital instructions tied to your PFMEA and control plan, always current and version-controlled. Industrial AI converts legacy PFMEAs and recorded training into structured instructions up to 77% faster.
Die makers and controls technicians are retiring, while lines retrain for EV programs. Poka gives L&D a structured, traceable onboarding and competency system at the point of work. You retrain at market speed and lift workforce retention by 38%.
45% faster onboarding | 38% higher workforce retention
A single line stop on a JIS program can cascade into OEM downtime and charge-backs. Poka captures issues with asset context and routes them automatically, with full history. Bosch Automotive cut issue management time 60%, improved Mean Time Between Repair 54%, and saved 200,000 euros a year.
20 to 40% faster issue resolution | Full audit trail from report to resolution
Poka AI answers operator questions from your own PFMEAs, control plans, and OEM manuals, in the flow of work. Purpose-built Agents guide structured troubleshooting and abnormal-event response. Complex, multi-variant assemblies come out right the first time.
How Poka Turns Daily Work Into Continuous Improvement
The best automotive suppliers get better with every program, not just faster today. That takes systems: every layered process audit, defect, and 5 Whys should make the next build more capable.
Poka creates that flywheel. It captures defects and near-misses at the source, with full context. Teams fix root causes, not just symptoms. Every corrective action becomes updated standard work, tied to your PFMEA. Operators add improvement ideas from the line, and structured daily management keeps those ideas visible.
Over time, PPM trends down. Changeovers tighten. Delivery reliability improves against every JIS window. Poka preserves skilled-trades knowledge as workers retire. Those gains flow straight to OEM scorecards, and to the bottom line.
Whether You Run the Line or the Plant, Poka Works for Your Team
Whether you're running a stamping press, leading quality at a Tier 1 powertrain plant, or rolling out operational excellence across a dozen manufacturing divisions, Poka adapts to the workflows your teams run.
Operators get the latest approved procedure for every SKU, line, and configuration, with the AI Assistant guiding changeovers and abnormal events and centerlining and start-of-production checks all in one place.Operators get the latest approved standard work for every part, station, and program. The AI Assistant guides complex assembly. Changeover discipline keeps every shift on time.
How Leading Automotive Companies and Manufacturers Use Poka
Bosch
Bosch Automotive: 60% faster issues and 200,000 euros saved
Bosch Automotive consolidated 20 disconnected tools into 2 integrated systems on Poka, and connected them to SAP and MES. Equipment data now syncs automatically. On the pilot line, issue management sped up 60%, saving 200,000 euros a year and improving Mean Time Between Repair by 54%. Bosch then rolled Poka out across all 12 manufacturing divisions.
Tetra Pak
Tetra Pak: Maintaining skills matrices with half the effort
Precision manufacturing depends on knowing exactly who's qualified to do what. Tetra Pak cut the man-hours it takes to maintain skill matrices by 50% on Poka, while tracking 1,200 skills per factory. That's a model automotive plants can use directly, for complex, multi-variant skill requirements.
USG
USG: Industrial AI to convert legacy content fast
Fast retraining depends on converting existing knowledge into usable instructions quickly. USG used Poka's Industrial AI to build 2,400 work instructions and save thousands of hours. Automotive plants use that same content-conversion engine, to keep PFMEA-aligned standard work current as programs change.
Go Deeper on Connected Work for Automotive Manufacturing
Frequently Asked Questions
Every Part That Leaves Your Plant Carries Your Name on It.
Poka helps automotive teams protect that name, shift after shift:
- Make sure every operator, on every shift, executes to the exact same standard
- Capture your most experienced people's knowledge before they retire
- Give new hires the confidence to run complex, multi-variant work correctly on day one
- Trace any concern back to its source, and back to a fix, in minutes
- Build your OEM relationship on trust
See how Poka protects what your team has built.
Poka is becoming our second-most important system after MES. It connects people, processes, and knowledge, all in one place.
Manager of Manufacturing Digitalization, Bosch Automotive
