1. Capture work orders instantly
Work orders are created automatically when an operator tags an issue or a scheduled PM is due, with photos, location, and equipment ID attached.
Daily issue management for professional maintenance: Move your maintenance team from reactive repairs to proactive reliability
Professional maintenance tags in LeanSuite turn radio calls and firefighting into work orders every technician can see, own and close out.
HOW IT WORKS
From work order to job done in three steps
One digital process, so every job has a clear owner from the first flag to the final fix.
2. Track every job in real time
Every new work order lands on a live maintenance dashboard, where you track status, technician assignments, and the whole backlog in one place.
3. Resolve and record every fix
Technicians document the fix, log parts used, and close the work order from any device, building a searchable repair history for every asset.
MAINTENANCE INTELLIGENCE
See your problem machines and improve first-time fix rates with AI
AI gives technicians better information before they reach the machine, and a live floor plan shows equipment health.
FLOOR PLAN VISUALIZATION
See your problem machines on the floor plan
Retire the maintenance whiteboard. Upload your facility layout and LeanSuite builds a live equipment health map showing which machines have the most open work orders.
LEAN AI IMAGE RECOGNITION
Better data from the floor, better repairs from your team
Operators snap a photo of a fault and Lean AI writes a detailed description, so technicians arrive with the right tools and context.
AUTOMATION
Automation that keeps every work order owned
Rules route each work order to the right technician, set its due date by priority, and stop it bouncing between people.
Auto-assignment
Route each work order to the right technician based on equipment, issue type, and skill set.
Auto due dates
Set due dates automatically from priority level, such as breakdown or PM, to keep SLAs on track.
Reassignment tracking
Cap how many times a tag can be reassigned, so repairs don't stall between technicians.
MAINTENANCE TAGS
A tag for every type of maintenance issue
Sort every issue by type for cleaner tracking and analysis, and create custom tags for any process or department.
Breakdowns
Flag equipment that is down and not producing.
PM generation
Spot where a new preventive maintenance task is needed.
Safety-related
Tag maintenance issues that pose a direct safety risk.
Quality-related
Flag equipment issues that are causing product defects.
A CONNECTED SYSTEM
Turn daily breakdowns into long-term reliability
Maintenance work feeds straight into your wider continuous improvement program.
Escalate to Kaizen
Same breakdown again? Escalate a recurring problem into a Kaizen or A3 project in one click and fix the root cause.
Record the spare parts used
Record the spare parts used in each repair on its emergency work order, next to what was repaired.
Analyze trends
Built-in dashboards show MTTR, MTBF, and other key metrics by machine or line, so you can find your worst-performing assets.
Your process. Every record linked.
Shape the workflow to your plant
RCA, Kaizen, work orders, tags and best practices follow your own steps, fields and approvals.
At each stage you set who can move it, what must be valid first, what updates on its own and who is told.
Enter it once
One issue becomes a tag, an RCA, a work order, a Kaizen and a best practice. Nobody retypes it.
Photos, SOP, checklist and signatures stay attached and linked.
Every module is connected to every other, so you enter the same information once and the paperwork stays linked to each document.
FAQs
Frequently Asked Questions
A professional maintenance tag is a repair request for the maintenance team, raised when equipment has a fault, a breakdown or another problem that needs a technician. In LeanSuite, each tag becomes a work order with photos, location and equipment ID attached, which a technician can see, own and close out.
Autonomous maintenance tags cover the care operators give their own equipment. Professional maintenance tags cover the repairs the maintenance team carries out, such as machine faults, leaks and breakdowns.
Rules route each work order based on the equipment, issue type and skill set, and set its due date from priority level, such as breakdown or PM. You can cap how many times a tag is reassigned, so repairs don't stall between technicians.
They document the fix, log the parts used and close the work order from any device. Over time this builds a searchable repair history for every asset.
Breakdowns, PM generation for spotting where a new preventive maintenance task is needed, safety-related issues and quality-related issues. You can also create custom tags for any process or department.
Escalate the recurring breakdown into a Kaizen or A3 project in one click and fix the root cause.
Log a breakdown as an emergency work order (EWO) with its start and end times. Downtime and MTTR are calculated, and the repair, parts used and root cause are recorded.
Yes. The AI RCA agent drafts the 5 Whys and 4M1D from the breakdown description and any attached manuals or SOPs, and you edit the result.
FREE RESOURCES
Free templates and tools
Not ready for software yet? Start with these free resources.
- Work order template for maintenanceA work order template for maintenance: one form per job from request to handback, and a log of response, completion and backlog by priority.
- Preventive maintenance checklist templateA PM checklist per machine with readings and sign-off, and a PM schedule that works out the next due date.
- Equipment downtime log (MTTR and MTBF)A breakdown and downtime log, with MTTR, MTBF and downtime by machine and cause worked out in Excel.
- Equipment criticality analysisAssets scored 1 to 5 on six criteria with your own weights, ranked and sorted into classes A, B and C with a safety override and a suggested maintenance strategy.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- RCM worksheet (failure mode and task selection)Failure modes classed as hidden, safety, operational or non-operational, then a task chosen for each: condition-based, discard, failure-finding, redesign or run to failure.
- Breakdown analysis reportOne equipment breakdown from the stop to the 90-day check, plus a breakdown log with repeat flags, MTBF and MTTR by asset and a Pareto of causes.
- Early equipment management 90-day model area planThirteen weeks from lessons on current machines to a tracked start-up on one model equipment project, a KPI board, the day-90 gate and expansion waves.
- Equipment register templateOne row per asset, with hierarchy, criticality, PM strategy and owner, and a check that flags what is missing.
- Machine history record templateOne record per machine: components and their life, every breakdown and repair with cost, MTBF and MTTR, and a repair-or-extend check.
- Compressed air leak survey logWalk sheet, printable leak tags and a tracker that puts an annual cost on every leak and follows it to a verified fix.
- Life cycle cost analysis templateCompare up to three machines over ten years: price, energy, upkeep, failures and down time, discounted to present value.
- Equipment design review checklistGate reviews for a new machine before order, before build and before start-up, with a safety buy-off and a problems journal.
- MTBF and MTTR calculatorMean time between failures, mean time to repair and availability from operating time, failures and repair time.
- Repair or replace calculatorEquivalent annual cost of keeping and repairing an old machine against buying a new one, with each one's economic life and the break-even figures.
Ready to build a stronger maintenance program?
See how LeanSuite brings clarity, collaboration, and control to your daily maintenance work.