Lean Analytics The Next Level of Continuous Improvement
Optimize where it matters most: The IQA Lean Copilot identifies key action areas for improvement and uncovers the root causes of complex performance issues.
Optimize where it matters most: The IQA Lean Copilot identifies key action areas for improvement and uncovers the root causes of complex performance issues.
The IQA Lean Copilot comes with a comprehensive library of ready-to-use Lean analyses tailored to the performance issues that matter most in production. Common cost and efficiency drivers - from bottleneck identification and loss analysis to WIP optimization and schedule adherence - are covered out of the box. No custom configuration, no analytical setup required. The analyses work immediately on the existing data and surface improvement opportunities that production teams can act on directly.
The IQA Lean Copilot does not stop at identifying improvement opportunities. Every finding can be explored through guided deep dives that trace the underlying cause step by step - with just a few clicks, no data specialist required. Results are fully transparent and explainable, so production managers and Lean specialists can follow the logic, challenge the findings, and build confidence in the analysis before committing to any measure.
Shopfloor management, Six Sigma, Kaizen, and continuous improvement processes are only as effective as the data behind them. The IQA Lean Copilot integrates directly into existing Lean routines - providing the data foundation that daily improvement work typically lacks. Deviations, losses, and open issues are visible in real time, so shopfloor meetings and Kaizen activities are based on facts rather than estimates. Measures can be tracked, progress becomes measurable, and knowledge is preserved across teams.
The IQA Lean Copilot applies built-in Lean methodology to continuously determine where the actual bottleneck lies: within a single value stream, across multiple value streams sharing the same workstations, and through the bill of materials down to upstream stages or sub-assemblies that are limiting overall throughput. Indicators such as utilization, cycle time, inventory coverage, and availability are combined and weighted according to established Lean principles, and can be adjusted to the specific conditions of each value stream. The bottleneck logic automatically accounts for the manufacturing type - whether line production, assembly, or job shop.
The IQA Lean Copilot places every loss directly in the context of the value stream, making it immediately clear whether a disruption is actually constraining throughput or occurring on a non-critical process step. Losses are categorized into technical, organizational, process-related, and quality losses and ranked by impact - so attention goes to where it matters most. For any workstation in the value stream, the full breakdown of disruption reasons and their temporal distribution is accessible with a single click - as a direct drill-down from the value stream map, without switching context or tools.
The IQA Lean Copilot continuously tracks Work-in-Process (WIP) based on real material flow data, not planned values. WIP is visualized at every stage of the value stream map, making tied-up capital visible and highlighting where material is accumulating in front of constraints.
At the supply chain level, IQA extends this view through the bill of materials - tracking intermediate inventories, storage times, and replenishment lead times for every sub-assembly and component feeding into the finished product. This makes it possible to identify oversized buffers, misaligned replenishment cycles, and upstream shortages before they put downstream production at risk.
The IQA Lean Copilot monitors actual cycle times across all value streams and automatically flags process steps that exceed the defined takt time - before they become a delivery reliability issue. Unlike isolated machine metrics, the IQA Lean Copilot always shows the connection to overall flow: where an elevated cycle time actually threatens throughput, where it is non-critical, and where it signals a growing schedule deviation. Deviations are visible in real time and can be traced back to specific orders, shifts, or machine conditions, making it straightforward to separate structural problems from one-off events.
The IQA Lean Copilot makes the full picture of setup performance visible across all workstations and product combinations, automatically and without manual data collection. Actual setup times are benchmarked against plan for every product changeover, optimal setup sequences become identifiable on the basis of an automatically generated setup matrix, and trends over time show whether improvement measures are actually taking hold.
The IQA Lean Copilot assesses material availability across the entire internal supply chain, from individual workstations through to finished product level. Through the bill of materials, it traces replenishment lead times, intermediate inventory levels, and material flows across all contributing production stages. When availability issues arise, it is possible to drill down directly into the relevant value stream to identify where in the chain the root cause lies, whether in a production bottleneck, an undersized inventory buffer, or a misaligned replenishment cycle between stages.
The IQA Lean Copilot makes performance gaps visible at every level of comparison that matters in production. Actual value streams are compared against routing plans to surface deviations in cycle times, lead times, and throughput, feeding directly back into master data improvement and closing the loop between what production actually does and what planning systems assume. Value streams, workstations, products or sites can be benchmarked against each other and against target values and best historical results, so improvement potential becomes immediately quantifiable rather than a matter of experience and gut feel.
Live digital value stream from existing production data - for continuous value stream analysis.
Autonomous AI-based monitoring, proactive alerts and actionable guidance.
Simulation of the impact of production changes directly on the Digital Value Stream, with no additional modeling effort.
