Micro-stops are brief machine stops, often under a few minutes, that quietly drag down OEE. In LeanSuite, operators log each one in one tap, and the stops are added up and costed so you fix the most expensive first.
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The Hidden Factory
Your ERP and MES catch major downtime. The 60-second jams that happen 40 times a shift add up to hours of lost capacity that never reach the management report.
Unmeasured Losses
Operators simply clear the jam and restart the machine without logging the event.
False OEE Scores
Your performance metric looks fine on paper, but you are constantly missing production targets.
Misguided Engineering
CI teams spend months speeding up a cycle time when the real issue is constant minor stops.
1-Click Capture
Operators log a micro-stop in two seconds without leaving their station.
AI-Driven Aggregation
LeanSuite groups hundreds of minor stops and puts a dollar value on the total.
Targeted Elimination
The data feeds Kaizen workflows, so teams can engineer out the nuisance stops.
HOW IT WORKS
Issue Management logs each minor stop with its category, duration and cause. Cost Management adds them up into a costed loss tree per machine. Kaizen & Projects turns the biggest losses into improvement projects.
Daily Issue Management
Real-Time Micro-Stop Capture
No more paper tally marks. Operators tap large buttons on a tablet to log a misfeed, sensor fault or minor jam the moment it happens.
Large, custom buttons for your most common faults
One tap per stop, then straight back to clearing the jam
Loss & Cost Management
Financial Impact Visibility
LeanSuite adds up the micro-stops, calculates the lost cycle time and puts a dollar value on it, building a live Pareto chart of your biggest hidden losses.
Micro-stops added up across lines and shifts
Lost time multiplied by each work center's cost rate
A live Pareto of your biggest hidden losses
Kaizen & Projects
Targeted Improvement Initiatives
With the losses visible, CI and engineering can launch targeted Kaizen events to fix the faulty sensor or misaligned guide rail behind the stops.
Launch Kaizen events straight from the loss data
Put CI and engineering time on the biggest losses
Remove root causes, not just symptoms
OEE Optimization
When you're sold out, a new line is a multi-million-dollar gamble. Removing micro-stops frees capacity from the equipment you already own.
Fix the Performance Metric
OEE is Availability × Performance × Quality. Micro-stops quietly drag down Performance, and LeanSuite shows why a machine isn't running at its ideal speed.
A Voice for Operators
Operators finally have the data to show management how often these "minor" stops happen.
High-Speed Manufacturing
If logging a stop takes longer than clearing the jam, operators won't do it, so LeanSuite's screens are built to be fast.
SOC 2 Type 1 report
First module live in under a week
Unlimited users per facility
99.5% Uptime SLA
FAQs
See how LeanSuite's connected modules find your micro-stops and win back OEE.
