Kaizen Copilot Station Design | AI-Powered Assembly Analysis for Lean Manufacturing

Improving workstation efficiency starts with understanding every step of the assembly process. In this video, we demonstrate how the Kaizen Copilot Station Design Module uses AI and computer vision to transform a simple smartphone video into detailed insights for lean manufacturing.

You’ll learn how the Station Design Module can:
• Automatically detect and break down cycles into meaningful assembly steps
• Separate value-add vs non-value-add activities for accurate time analysis
• Provide cycle statistics, including mean and mode times, at both process and step levels
• Compare different part numbers side by side to identify variations in performance
• Export results directly into Excel templates, customized to your company’s formats
• Generate AI-driven improvement suggestions, such as tool positioning or using more efficient equipment
• Produce spaghetti diagrams and workstation heat maps to visualize operator movement and layout usage
• Estimate potential cycle-time reductions from implementing improvements
• Deliver all results and recommendations in a downloadable PDF report

The Station Design Module not only highlights inefficiencies but also teaches continuous improvement by asking the right questions, surfacing Kaizen opportunities, and helping teams reimagine workstation layouts.

With Kaizen Copilot, manufacturers can reduce waste, optimize workflows, and empower engineers with AI-powered insights for smarter decision making.

🔗 Learn more: https://retrocausal.ai/station-design...

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