Arias Kaikaku Consulting
 

Transforming Operations Through AI and Financial Intelligence

AI Copilot | Digital Kaizen | Financial Intelligence | Operational Resilience | Sustainable Profitability
Every transformation we lead is defined by precision, resilience, and measurable value creation.

Discover how we help organizations accelerate performance, unlock actionable financial intelligence, and sustain a lasting competitive advantage.

General Motors – Redefining Smart Manufacturing Through AI, Digital Twins, and Kaizen Excellence

1. Situation

• General Motors faced recurring production bottlenecks and inconsistent performance across its North American assembly plants.

• Outdated MRP systems prevented real-time synchronization between demand, production, and maintenance.

• ERP, MES, and maintenance systems were not integrated, limiting executive visibility and delaying decision-making.

• These inefficiencies eroded approximately $38 million in EBITDA annually.

2. Diagnostic and Insights

• Arias Kaikaku Consulting analyzed three years of operational, maintenance, and logistics data across nine GM plants.

• 42% of downtime events were predictable using machine telemetry and process signals.

• Maintenance was reactive and calendar-based, causing over-maintained assets and idle time.

• Throughput variation between plants reached 22% due to uneven shift-level balancing.

• Average decision latency per disruption exceeded four hours.

3. Solution: Digital Kaizen Copilot Framework

• Designed an AI-driven ecosystem integrating scheduling optimization, digital twins, and continuous Kaizen execution.

• Built a full-scale digital twin simulating production lines, machines, and material flows.

• Developed an AI Copilot using reinforcement learning to predict bottlenecks up to eight hours in advance.

• Embedded predictive maintenance analytics to trigger interventions based on condition, not time.

• Provided operators with AI-generated Kaizen prompts and dashboards linking KPIs to financial metrics.

• Delivered executive dashboards connecting operational decisions to real-time financial impact.

4. Results and Impact

• Downtime reduced by 32%.

• Throughput increased by 19%.

• OEE improved from 68% to 81%.

• Waste reduced by 29%.

• Working capital reduced by 13%.

• EBITDA uplift of $38 million per year.

• Return on Assets increased by 1.4 percentage points.

5. Strategic Transformation

• GM transitioned from reactive management to an AI-enabled, self-learning manufacturing network.

• 74% of scheduling decisions became automated.

• Leadership visibility fully integrated with financial outcomes.

• Set a new global standard in digital manufacturing excellence.

6. Next Phase

• Expansion of the AI Copilot framework to EV and battery operations.

• Projected additional EBITDA uplift of $120 million annually.

• Global rollout of the Digital Kaizen Copilot model.
   

Foxconn Technology Group – Building Predictive Resilience in a Global Supply Network

1. Situation

• Foxconn experienced frequent production delays caused by component shortages and supplier unreliability.

• Its global supply network lacked unified data visibility.

• Over $100 million in annual disruption costs and excess working capital reduced profitability.

2. Diagnostic and Insights

• 38% of shortages were predictable via lead-time pattern analysis.

• Supplier reliability varied by 40% across categories.

• 26% of inventory was obsolete or non-moving.

• Planning and procurement decisions suffered a latency of more than 72 hours.

3. Solution: Predictive Supply Chain Intelligence Platform

• Unified sourcing, inventory, and logistics data across 18 countries.

• Built machine-learning models to forecast shortages weeks ahead.

• Implemented a Supplier Risk Scoring Engine combining financial, geopolitical, and performance indicators.

• Embedded an AI Copilot for S&OP to provide real-time procurement and allocation recommendations.

• Introduced Dynamic Buffering to adapt reorder points to disruption risk and cost-to-serve.

• Created a Global Control Tower linking supplier health, production priorities, and financial performance.

4. Results and Impact

• Disruption costs decreased by 41%.

• Component availability reached 98.7%.

• Forecast accuracy improved by 22%.

• Working capital optimized by $52 million.

• Improved liquidity, agility, and service reliability.

5. Strategic Transformation

• Foxconn evolved from reactive supply management to predictive resilience.

• Predictive analytics became embedded in executive S&OP.

• Strengthened long-term resilience, financial flexibility, and ESG alignment.

6. Next Phase

• Integration of carbon intensity and sustainability analytics into the AI Copilot framework.

• Positioning Foxconn as a global leader in intelligent, sustainable supply chain management.

Nestlé S.A. – Driving Quality and Efficiency Through AI and Lean Digital Transformation

1. Situation

• Nestlé faced increasing production costs and inconsistent quality across global manufacturing plants.

• Manual inspections and legacy systems generated rework, waste, and rising process variability.

2. Diagnostic and Insights

• 29% of defects were caused by preventable process variation.

• OEE performance lagged global benchmarks.

• Limited analytics and workforce skill gaps slowed quality improvement cycles.

3. Solution: AI-Driven Quality Copilot

• Combined computer vision, machine learning, and Lean Six Sigma methods into a unified system.

• Implemented real-time anomaly detection with over 98% accuracy.

• Built predictive models linking process parameters to defect probability.

• Created a Digital Kaizen Layer providing guided root-cause prompts and financial impact visibility.

• Trained 800 employees in digital Lean improvement.

• Connected all improvements to profitability and cost-to-serve metrics through Financial Intelligence dashboards.

4. Results and Impact

• Waste reduced by 29%.

• OEE increased by 26%.

• Achieved annual operational savings of $41 million.

• Quality consistency significantly improved.

• Employee engagement and accountability strengthened.

5. Strategic Transformation

• Shifted from inspection-based to predictive quality management.

• Embedded data-driven decision-making into day-to-day operations.

• Established a global model for AI-enabled Lean Manufacturing.

6. Next Phase

• Global expansion of the AI Quality Copilot.

• Integration of sustainability and energy efficiency analytics.

• Alignment of quality performance with ESG and profitability goals.
   

Strategic Vision: Building Intelligent Performance

At Arias Kaikaku Consulting, we help global enterprises transition from efficiency-driven to intelligence-driven operations.
Our mission is to transform performance at the intersection of AI, Kaizen, and Financial Intelligence, creating companies that think, learn, and grow profitably.

Let’s Work Together

Let’s redefine what performance means in your organization.
If your goal is to make your enterprise faster, smarter, and financially stronger, let’s connect.
Together, we can build a self-learning organization — where every decision is intelligent, every process creates value, and every result is measurable.