All projectsMercedes-Benz Türk
Using AI in Kaizen Processes
A generative AI training and workshop program for approximately 150 foremen at Mercedes-Benz Türk's İstanbul and Aksaray factories. Kaizen and lean thinking were explored with AI through real shop-floor cases.
At a glance
- Project Focus
- Transformation with AI · Problem-Solving
- Solution Area
- Transformation with AIProblem Solving with TRIZ
- Project Lead
- TrainerY. Bora Kaykayoğlu
- Approaches Used
- Facilitation
- What Emerged
- Mercedes-specific AI agent preparations · Process analyses based on the seven types of waste · Group case solutions and presentations
- Sector
- Automotive
- Year
- 2025
Inside the project
Focus
How can foremen connect AI with shop-floor improvement practices?
The program was designed to help production foremen connect generative AI directly with shop-floor operations. The focus was on linking AI to the daily improvement practices of Kaizen and lean thinking.
AI becomes part of improvement practice when paired with the right questions to make waste visible.
Scope
We worked with foremen at the Istanbul and Aksaray factories on generative AI, Kaizen and lean thinking, using real cases from the shop floor. Through training and workshops, we explored AI as a decision-support and problem-solving tool in production line management, seat manufacturing, paint shop operations, finishing, quality and maintenance.
Implementation
The seven types of waste, with AI
Participants worked on cases from production line management, seat production, paint shop, finishing, quality and maintenance. Processes were analyzed with AI using the seven types of waste framework, improvement opportunities were identified, and groups presented their solutions.
The journey we designed
- 01EXPLOREReal shop-floor cases from production, quality and maintenance were selected according to each group's participant profile.
- 02REFRAMEAI was positioned not as a ready-made answer tool but as a decision-support tool that helps redefine problems and make waste visible.
- 03BRING IT INTO THE ORGANIZATIONGroups developed AI agent preparations and improvement proposals for Mercedes-specific cases and presented their results.
Kaykayoğlu project insight
Kaizen's strength lies in small improvements. AI helps us spot them faster.
Explore further
Selected resources that examine the transformation highlighted by this project from a broader perspective.