Increase Productivity
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%
Reduce Rework
0
%
Decrease Lead Time
0
%
Lower Risk Score
0
%
Your AI Partner for Continuous Process Improvement
Helping Industrial Engineers Supercharge Station Design and Process Optimization Using Smartphone Video
Your AI Partner for Continuous Process Improvement
Helping Industrial Engineers Supercharge Station Design and Process Optimization Using Smartphone Video
Boost Industrial Engineers’ Productivity by 4X
Get out of Excel and stopwatches and experience a full analysis done in minutes with ease. Our AI-powered platform removes the need for manual data collection while combining the capabilities of multiple software into one easy-to-use platform. Kaizen Copilot empowers industrial engineers to conduct faster time and motion studies, FMEA generation, ergonomic analysis, and much more.
Conduct Rapid Time and Motion Studies
Use advanced computer vision technology to conduct video-based time and motion studies with a single video of a cycle. Get instant recommendations and implement improvements faster.
- Quickly understand your actual cycle time broken out by value-add vs non-value add time.
- Easily share task and time data with the line balancing module
- Get workstation and process design recommendations.
Conduct Rapid Time and Motion Studies
Use advanced computer vision technology to conduct video-based time and motion studies with a single video of a cycle. Get instant recommendations and implement improvements faster.
- Quickly understand your actual cycle time broken out by value-add vs non-value add time.
- Easily share task and time data with the line balancing module
- Get workstation and process design recommendations.
Rebalance Existing Lines
Rapidly design new lines or rebalance existing ones. Simply input the steps on the line and Kaizen Copilot will:
- Generate a precedence diagram
- Instantly identify the time taken at each station
- Highlight the bottleneck station
- Create an insightful Yamazumi chart
- Tailor lines by adjusting for Takt time, volume or operator.
Rebalance Existing Lines
Rapidly design new lines or rebalance existing ones. Simply input the steps on the line and Kaizen Copilot will:
- Generate a precedence diagram
- Instantly identify the time taken at each station
- Highlight the bottleneck station
- Create an insightful Yamazumi chart
- Tailor lines by adjusting for Takt time, volume or operator.
Simplify Work Instructions, Empower Operators
Leverage the Digital Work Instructions Solution to create accurate, up-to-date instructions without manual documentation:
- Automatically generate step-by-step work instructions from a single video capture.
- Ensure instructions are always current, even in fast-changing or high-mix environments.
- Reduce errors and rework by providing clear, standardized guidance at every workstation.
- Instantly export and share instructions for training, audits, or continuous improvement.
Simplify Work Instructions, Empower Operators
Leverage the Digital Work Instructions Solution to create accurate, up-to-date instructions without manual documentation:
- Automatically generate step-by-step work instructions from a single video capture.
- Ensure instructions are always current, even in fast-changing or high-mix environments.
- Reduce errors and rework by providing clear, standardized guidance at every workstation.
- Instantly export and share instructions for training, audits, or continuous improvement.
Cut Wasted Steps, Boost Productivity
Leverage the Floor Analysis Solution to identify movement inefficiencies and design smarter layouts without manual tracking:
- Automatically track operator movement and generate spaghetti and string diagrams.
- Visualize walking, working, and idle time for each operator to pinpoint bottlenecks.
- Receive layout recommendations to reduce walking distance and improve workflow.
- Generate actionable reports to guide floor layout adjustments.
Cut Wasted Steps, Boost Productivity
Leverage the Floor Analysis Solution to identify movement inefficiencies and design smarter layouts without manual tracking:
- Automatically track operator movement and generate spaghetti and string diagrams.
- Visualize walking, working, and idle time for each operator to pinpoint bottlenecks.
- Receive layout recommendations to reduce walking distance and improve workflow.
- Generate actionable reports to guide floor layout adjustments.
Expedite and Simplify MODAPTS Analysis
Utilize our AI-driven digital tools to expedite and enhance Predetermined Motion Time Studies with MODAPTS, MTM, and MOST.
- Establish standard times and streamline workflows.
- Automatically convert text description of processes to PMTS symbols.
- Translate between different PMTS standards.
Expedite and Simplify MODAPTS Analysis
Utilize our AI-driven digital tools to expedite and enhance Predetermined Motion Time Studies with MODAPTS, MTM, and MOST.
- Establish standard times and streamline workflows.
- Automatically convert text description of processes to PMTS symbols.
- Translate between different PMTS standards.
Design Safer Shop Floors
Leverage the comprehensive ergonomics suite to promptly identify risky postures and implement timely intervention without manual data collection:
- Automatically conduct various analyses including REBA , RULA, NIOSH lifting equation, Snook tables and Hand Strain Index
- Get valuable insights into weaker postures and streamline job redesign accordingly.
- Instantly generate and export reports.
Design Safer Shop Floors
Leverage the comprehensive ergonomics suite to promptly identify risky postures and implement timely intervention without manual data collection:
- Automatically conduct various analyses including REBA , RULA, NIOSH lifting equation, Snook tables and Hand Strain Index
- Get valuable insights into weaker postures and streamline job redesign accordingly.
- Instantly generate and export reports.
Proactively Identify and Address Potential Failures
Take advantage of the built-in comprehensive library of failure modes to anticipate potential risks and issues within seconds instead of days.
- Rapidly retrieve failures identified in previous projects
- Use AI suggest to automatically assign severity level to each step
- Instantly replay station videos for process clarifications
Proactively Identify and Address Potential Failures
Take advantage of the built-in comprehensive library of failure modes to anticipate potential risks and issues within seconds instead of days.
- Rapidly retrieve failures identified in previous projects
- Use AI suggest to automatically assign severity level to each step
- Instantly replay station videos for process clarifications
Maximize your Engineers’ Valuable Time on Action Planning
Kaizen Copilot automatically identifies process issues, proposes solutions, and documents the entire journey beyond implementation, so your industrial engineers don’t waste time on non-value adding tasks.
Increase Productivity
0
%
Reduce Rework
0
%
Decrease Lead Time
0
%
Lower Risk Score
0
%
Boost in IE Productivity
0
x
Faster time & motion Studies
0
x
Cheaper ergonomic analysis
0
%
Eliminate documentation cost
0
%
Better Internal collaboration
0
%
No new equipment required.
Industrial engineers can capture video using an ordinary smartphone that’s affixed in a stationary position. You can also use a standard external webcam.
User-friendly interface.
Kaizen Copilot is wizard-driven and has a very short learning curve. Any industrial engineer can immediately get started with it without extensive training.
Robust security.
Retrocausal’s platform is ISO 27001 certified, built on Amazon Web Services’ secure cloud infrastructure, and is compatible with Azure Active Directory, Okta, and IBM QRadar for enterprise security.
Accessible from anywhere.
Kaizen Copilot is a cloud-native software, which means IEs can access it from anywhere they have an internet connection.
Complete Analysis with Kaizen Copilot in Minutes
Record
Record your workstation cycle from a smartphone and upload it on the platform.
Analyze
The video segmentation technology will automatically parse the video into meaningful steps and conduct analysis.
Optimize
View each of the station design, ergonomics, FMEA and line balancing results and recommendations in minutes.
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Case Studies
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Kaizen Copilot
Your AI Partner for Continuous Process Improvement
Leverage LeanGPT™ foundation models, shop-floor analytics, and secure knowledge base training to generate valuable documentation, analyses and ideas through a conversational interface.
Quick & Easy Setup
Why Kaizen Copilot?
Are you challenged with more Industrial Engineering (IE) projects than you have IE staff?
How well do you cross-pollinate knowledge gained at different facilities or different shifts?
After a Kaizen event, how quickly do you reanalyze the process and give feedback to the team?
If you find yourself worrying about any of these questions, Kaizen Copilot is for you.
What is Kaizen Copilot?
Industrial Engineers and Production Managers design, track, and optimize industrial processes by combining domain expertise, organizational knowledge, and tedious manual observations such as time studies, ergonomic assessments, and yield estimates, while reasoning in a Lean Six Sigma and TPS framework.
We have trained a new kind of Generative AI foundation model called LeanGPT™, specialized for the manufacturing and industrial engineering domains. Kaizen Copilot is a patent-pending assistive AI agent built on the LeanGPT model which gives it expert-level IE domain knowledge. We provide our customers the option to connect LeanGPT to their organizational knowledge bases in a secure and potentially even “on-premise” configuration. Further, Kaizen Copilot connects our computer vision and IoT-sensing platform to LeanGPT to minimize the need for manual measurements on the factory floor. We bake Lean Six Sigma workflows into Kaizen Copilot so that it can assist IEs in following widely accepted best practices.
What can Kaizen Copilot do for me?
1
Act as a virtual IE consultant for small sized manufacturers who cannot afford to hire one full-time.2
Generate analyses such as FMEA, ISO-4501, Error-Proofing in seconds which typically take days and weeks to produce.
3
Simulate alternatives to your actual assembly line and calculate what may be achievable.3
Simulate alternatives to your actual assembly line and calculate what may be achievable.4
Identify commonalities in quality and line balancing problems amongst your factories which may appear unrelated at a first glance.4
Identify commonalities in quality and line balancing problems amongst your factories which may appear unrelated at a first glance.5
Assist your Industrial Engineers in the adoption of Lean Six Sigma and Toyota Production Systems best practices.6
Maximize the value out of operator interactions on your Gemba walks.7
Generate novel insights for productivity maximization by combining your organizational knowledge with all your digital factory data.8
Run OEE and Pareto Analysis by combining data from ERP, MES, and manual reporting.9
Facilitate compliance with regulatory standards by minimizing the time needed to generate relevant planning and audit documents.How does it work?
You can think of Kaizen Copilot as “ChatGPT for Industrial Engineering”, with the following improvements:
Specialized for Manufacturing
Kaizen Copilot is built on our own Large Language Models called LeanGPT, much like ChatGPT is built on GPT-3. However, LeanGPT is specialized on manufacturing and industrial engineering texts as well as proprietary industrial Kaizen form datasets.
Talks to IoT Infrastructure
While ChatGPT is frozen in time, and unable to fetch data from external sources like the internet, LeanGPT is able to call external APIs specifically Pathfinder’s computer vision and IoT platform as well as an increasing number of third-party SCADA platforms to formulate its responses.
References Actual Documentation
In addition to (or in place of) training LeanGPT on your knowledge bases, you can also use it to search individual documents in these repositories. In this mode, you retrieve documents that correspond to specific queries, and then ask questions from these documents. As opposed to ChatGPT, this gives you specific documents that you can cite as sources of conclusions.
Built-in Lean Six Sigma Workflows
Kaizen Copilot gently nudges its users in the direction of Lean Six Sigma and Toyota Production Systems best practices by suggesting appropriate “Example Prompts”. Further, we have built in templates and tools that allow you to automatically fill out appropriate Lean Six Sigma and TPS-inspired worksheets e.g. Process Capability Sixpack Reports or OEE charts. You are able to refine these worksheets by conversing with LeanGPT and shuffling data around as needed.
Trains on Organizational Knowledge Bases
LeanGPT can be trained your knowledge bases including ERP, MES, QMS, and CI systems in a secure cloud or on-premise configuration. Training LeanGPT models allows it to simultaneously consider all your organizational knowledge (potentially including knowledge across factories) together with its own manufacturing domain expertise and shopfloor observations in formulating questions to your answers. This, by definition, is a super-human capability that allows it to discover new connections and arrive at novel insights and conclusions.
Get access to the leading video analytics platform for your factory floor.
