Chemicals: Lean manufacturing software for chemical plants
LeanSuite runs the daily routines of a chemical manufacturing plant in one place. It covers operator rounds, batch and filling-line losses, off-spec batches, near misses, lockout and controlled procedures. It works beside your process safety management program and control systems, and it does not run PSM, management of change or permits.
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The problem
What slows chemical plants down
Specialty and batch chemical plants run hazardous materials through a few reactors and a filling line, with procedures that must be followed exactly every time. Here is where that slows them down.
Slow batches and filling-line stops
The same product takes hours longer one week than the next on the bottleneck reactor, because of waits for lab results, operators, utilities or a free tank. Downstream, filling lines lose time to short stops nobody records.
Off-spec batches and rework
A batch misses its viscosity, color or assay, so it is held, adjusted, blended off or reworked. Each fix costs reactor time and raw materials, and when the cause is not traced the same miss returns on the next campaign.
Near misses, small releases and process-safety signals
Small leaks, bypassed alarms, a relief valve that lifted or a near miss during unloading are warnings before a serious event. If reporting is a hassle they go unreported, and actions from incidents and audits sit open for months.
Cleaning and product changeovers
Moving from one product to the next means draining, washing, flushing and checking vessels, lines and filters before the next charge. Cleanouts that run long, or are judged clean by eye, cost reactor time and cause contamination.
Operating procedures that drift from practice
Procedures are written once and revised when an auditor asks, while the way operators actually run a step changes shift by shift. New operators learn from whoever trains them, and the written version falls behind.
Pump, seal and valve leaks
Pumps, seals, valve packing and flanges leak a little before they fail. Rounds done from memory miss the early signs, and the same bad-actor pumps get repaired again and again.
How LeanSuite helps
How LeanSuite helps chemical plants
Each problem maps to a LeanSuite module you can start with on its own, then connect to the rest.
Slow batches and filling-line stops
In LeanSuite: Operators log each minor stop in one tap with its category, duration and cause. Import your loss data and LeanSuite builds a loss tree that puts a cost on each loss, then tracks the savings as you remove them, and a high-impact loss starts a Kaizen event in one click.
Off-spec batches and rework
In LeanSuite: Each non-conformance is captured at the line and linked to a CAPA with root cause analysis. Issue Management routes it, Kaizen & Projects runs the CAPA, and Learning Management pushes the fix to every affected operator. The QA Matrix gives every internal and customer defect an AA, A, B or C priority, so the costly ones are fixed first.
Near misses, small releases and process-safety signals
In LeanSuite: Anyone logs a near miss, unsafe act or unsafe condition on their phone in seconds by scanning a QR code, and each corrective action is tracked until it is closed. Lean Creator runs lockout procedures as photo-verified isolation steps, and only trained, authorized people can start a lockout. LeanSuite does not run your PSM program, management of change or permits; it keeps the reports, audits and actions around them.
Cleaning and product changeovers
In LeanSuite: Run each cleaning and product changeover as a digital checklist in Lean Creator, and Issue Management flags missing items. Every checklist logs how long each step took, so Kaizen & Projects shows which steps to attack.
Operating procedures that drift from practice
In LeanSuite: Film the task once and LeanSuite drafts an SOP with purpose, scope, PPE, warnings and a photo for each step, then versions it and collects each person's signature. Drafts route to engineering, EHS and quality for e-signature, with an audit trail and version history, and the skills matrix shows who is qualified on each job.
Pump, seal and valve leaks
In LeanSuite: Digital CILR checklists put each machine's clean, inspect, lubricate and retighten routine on the operator's Daily Standard Work, and operators flag an abnormality with a photo without leaving the checklist. Professional maintenance tags turn radio calls and firefighting into work orders every technician can see, own and close out.
CILR ChecklistsProfessional Maintenance TagsAutonomous Maintenance
Customers
Companies that use LeanSuite
Whirlpool case study
How Whirlpool tackled project visibility and continuous improvement across 14 manufacturing plants with LeanSuite.
Its Global Kaizen Power Pitch saw 150 Kaizen presented, $14.8M in hard savings and $17.6M in soft savings.
14
Manufacturing plants
150
Kaizen presented at the Global Kaizen Power Pitch
$14.8M
Hard savings
$17.6M
Soft savings
What getting started looks like
Under a week
Until your first module is live; our team does the setup
$3,000
90-day pilot per facility
One flat price per facility
Unlimited users, so adding people does not change the price
99.5%
Monthly uptime commitment in the service agreement
SOC 2 Type 1 audited, hosted on secure cloud infrastructure, with single sign-on through Microsoft Entra ID or Okta and employee-ID sign-in for operators without email. Details on the security page.
Want to try it on one line first? See how the 90-day pilot works.
Free tools
Related free calculators
Work out the numbers behind these problems. Each calculator shows its formula and a worked example, with no sign-up.
Risk matrix calculator
Severity times likelihood on a 3 x 3, 4 x 4 or 5 x 5 risk matrix, the band and its action, editable banding, and the score after further controls.
Open calculatorTRIR and DART rate calculator
OSHA recordable and DART incident rates from your 300A case counts and hours, and what one more case does to them.
Open calculatorOEE calculator
Overall equipment effectiveness from shift time, downtime, ideal cycle time and part counts.
Open calculatorDowntime cost calculator
What an hour, an event and a year of unplanned downtime cost, from lost output, idle labour, scrap and overtime.
Open calculator
FAQ
Questions from chemical plants
No. LeanSuite does not run PSM, management of change or permits, and it is not a process safety or quality management system. It runs the daily routines around them: operator rounds and equipment checks, near-miss reports, audits with photo evidence, lockout steps and corrective actions tracked to closure. Changes to chemistry, equipment or procedures still go through your own change procedure.
Yes. LeanSuite drafts an SOP from a video of the task, with purpose, scope, PPE, warnings and a photo for each step. Drafts route to engineering, EHS and quality for e-signature, each version is kept with an audit trail, and each person's signature is collected. LeanSuite does not claim a validation on your behalf.
No. LeanSuite does not read control systems, sensors or lab systems, and it is not an MES. Operators log rounds, stops, defects and checks on a phone or tablet, and LeanSuite runs the improvement work around the systems you already have.
Yes. LeanSuite runs in the browser and has mobile apps on the App Store and Google Play, so rounds and checks are done on a phone or tablet. Which devices are allowed in each area, including classified areas, is set by your own site rules.
LeanSuite is one flat price per facility with unlimited users, so every operator on every shift can use it without adding seats. There is no published annual price; you can request a quote on the pricing page. The first module is live in under a week, and LeanSuite's team does the setup. A 90-day pilot costs $3,000 per facility.
See LeanSuite on your rounds, batches and near misses
Bring the routine you want to fix first. We will show you how LeanSuite handles it and what a 90-day pilot would cover.