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LeanSuite - Lean Manufacturing Software

Reducing COPQ: Stop Sorting Bad Parts. Start Eliminating Them.

Reduce the cost of poor quality (COPQ) by fixing the defects that cost most: LeanSuite's QA Matrix puts a dollar cost and a priority on each defect and shows engineering what to fix first.

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The Hidden Drain

The cost of poor quality you can't see

Buried in paper NCRs and spreadsheets, engineers work on the loudest problems, not the most expensive ones.

The reactive trap

  • Hidden Financial Impact

    You know you had 50 defects, but not what they cost.

  • Misaligned Priorities

    Engineers fix a minor nuisance while a margin-killer goes unnoticed.

  • Repeat Offenses

    Defects get scrapped, the root cause stays, and they come back.

The LeanSuite edge

  • Financial Prioritization

    The system automatically converts defect counts into hard dollar losses.

  • Data-Driven Focus

    A live Pareto chart shows your CI team which defects cost the most.

  • Closed-Loop Execution

    Highest-cost defects are pushed directly into DMAIC or Root Cause Kaizen workflows.

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HOW IT WORKS

Three modules, one quality loop

Issue Management logs each defect where it is found, the QA Matrix costs and ranks it, and Kaizen & Projects runs the root-cause project.

Issue Management
QA Matrix
Kaizen & Projects

Issue Management

Real-Time Defect Tracking

Log defects at the line

Operators log each defect at the line by part number and failure code.

  • Scan the QR code on the machine and the form opens with location, department and shift filled in

  • Defects are logged as they happen, not tallied on paper

  • No end-of-shift typing into Excel

Quality Matrix COPQ Pareto ranking defects by cost, with the scrap and rework cost behind the top defect

QA Matrix

Financial Impact & Prioritization

A live COPQ Pareto, ranked by cost

The QA Matrix combines internal defects and customer complaints, applies your standard costs and ranks each defect AA, A, B or C by where it was caught, severity, cost and recurrence.

  • Internal defects and customer complaints in one list

  • Your standard costs turn defect counts into dollars

  • A live Pareto of your cost of poor quality (COPQ)

  • The most expensive issue always sits at the top

Kaizen & Projects

Root Cause & Continuous Improvement

Launch the fix from the top offender

Launch a Kaizen or CAPA from the costliest defect, with the AI RCA Agent to find its root cause.

  • Launch a project in one click from the top cost offenders

  • 8D or A3 structure, with the team assigned at launch

  • Each project stays linked to the defect data behind it

  • Work on root causes, not firefighting

An 8D project launched from the top defect on the COPQ Pareto, with its team assigned
Savings validation for one defect code: weekly scrap and customer-return cost before and after the Kaizen closed

Financial Alignment

Connect the Shop Floor to the Bottom Line

LeanSuite links the defects operators log to the P&L.

Combine Internal & External Data

See in-process scrap next to warranty claims and customer returns on one dashboard.

Validate the Savings

After a Kaizen project closes, LeanSuite tracks that defect code for 90 days and reports the dollar savings of the fix.

IATF, ISO AND AS9100 READY

Built for zero-defect environments.

LeanSuite was designed by manufacturing veterans to support IATF 16949, ISO 9001 and AS9100, with the auditable digital trail external auditors ask for.

  • SOC 2 Type 1 report

  • First module live in under a week

  • Unlimited users per facility

  • 99.5% Uptime SLA

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Key terms

Lean glossary

FAQs

Frequently Asked Questions

FREE RESOURCES

Free templates and tools

Not ready for software yet? Start with these free resources.

Ready to Stop the Hidden COPQ Drain?

See how LeanSuite's QA Matrix turns defect data into a dollar-ranked action plan.

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