Client Value Delivered

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• Outdated MRP systems prevented real-time synchronization between demand, production, and maintenance.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

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.