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Daily issue management for quality: Catch and correct defects as they happen

Quality tags in LeanSuite give operators one simple way to flag defects, non-conformances and quality deviations the moment they see them, and track each to a corrective action.

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HOW IT WORKS

From defect found to CAPA closed in three steps

Every quality issue follows one workflow, so everyone knows the next step.

  • 1. Tag it on the spot

    Anyone can scan the QR code on a machine or part container, snap a photo, categorize the non-conformance, and add a quick note.

  • 2. Track it in real time

    Each flagged defect creates a Non-Conformance Report (NCR) on a live quality dashboard, and the Quality team and area supervisors are notified automatically.

  • 3. Resolve with a CAPA

    Assign Corrective and Preventive Actions (CAPAs) with due dates and collaborate in the ticket, leaving an auditable trail for compliance.

AI AND VISUALIZATION

See where defects happen, and report them faster

A live floor plan shows where defects cluster, and Lean AI writes the defect description from a photo.

Plant floor plan shaded as a quality heat map, with the paint booth and Press 4 marked as defect hotspots

FLOOR PLAN VISUALIZATION

See where defects cluster on your floor

Upload your facility layout and it becomes a live quality heat map, so you can spot high-risk areas and decide where to focus improvement first.

Quality tag with an attached photo, and Lean AI's Image Description of a burr on a bracket edge

LEAN AI IMAGE RECOGNITION

Let Lean AI be your eyes on the floor

Operators snap a photo of the defect and Lean AI writes a detailed description, so every defect report is consistent and quick to file.

AUTOMATION

Automation that keeps every NCR and CAPA owned

Rules route each NCR to the right engineer, set CAPA due dates, and stop corrective actions bouncing between people.

NCR routing by defect type and location, sending an out-of-tolerance hole on a bracket to the press shop quality engineer

Auto-assignment

Route each NCR to the right Quality Engineer or team based on defect type and location.

Auto due dates

Set CAPA due dates automatically from priority, so the most urgent actions are handled first.

Reassignment tracking

Cap how many times a CAPA can be reassigned, so it can't bounce between people.

QUALITY TAGS

A tag for every type of quality issue

Sort every quality issue by type for cleaner tracking and analysis, and create custom tags for any process or department.

  • In-process defects

    Capture defects found during the manufacturing process.

  • Supplier issues

    Flag non-conforming materials from your suppliers.

  • Customer complaints

    Document quality issues reported by your customers.

  • Audit findings

    Flag non-conformances found during internal or external audits.

A CONNECTED SYSTEM

Turn daily quality issues into long-term improvements

Daily quality issues feed straight into your wider continuous improvement work.

Recurring burr defect escalated into a new 8D project with its disciplines listed

Escalate to 8D/DMAIC

Same defect again? Escalate a recurring problem into an 8D or DMAIC project in a few clicks and fix the root cause.

Supplier issue tag on incoming castings creating a Supplier Corrective Action Request

Trigger supplier corrective actions

When a supplier issue is identified, it can automatically trigger a Supplier Corrective Action Request (SCAR) workflow.

Defect trends dashboard by line, shift, and defect type

Analyze trends

Break defect data down by line, shift, or type to find your biggest opportunities to reduce the Cost of Poor Quality.

Related

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.

Animation: a work order, Press 4 breakdown, moves from Open to In progress to Verified. At each gate four rules light up in turn: who moves it, what is checked first, what updates itself 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.

Animation: an oil leak at Press 4, Line 2 is typed once as a tag. It then links into a root cause analysis, a work order, a Kaizen and a best practice. A photo, SOP, checklist and signature stay attached to every record.

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

  1. A quality tag is a quick report of a defect, non-conformance or other quality deviation, raised by whoever spots it. In LeanSuite, each tag creates a Non-Conformance Report (NCR) on a live quality dashboard and is resolved with a Corrective and Preventive Action (CAPA).

  2. Anyone on the floor. They scan the QR code on a machine or part container, snap a photo, categorize the non-conformance and add a note, and the Quality team and area supervisors are notified automatically.

  3. In-process defects, supplier issues, customer complaints and audit findings. You can also create custom tags for any process or department.

  4. You assign each CAPA with a due date and work on the fix together in the ticket, which leaves an auditable trail for compliance. CAPA due dates can be set automatically from priority, and you can cap how many times a CAPA is reassigned.

  5. Break defect data down by line, shift or type to find your biggest opportunities to reduce the Cost of Poor Quality. Lean AI writes the defect description from a photo, so reports are consistent.

  6. Yes. A CAPA can run as a project with its own approval workflow, root cause sections such as 5 Whys, and an action plan.

Ready to build a stronger quality culture?

See how LeanSuite brings clarity, collaboration, and control to your daily quality operations.

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