Client Value Delivered

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.