The "Hidden Factory" is destroying your OEE. Leansuite gives operators a frictionless way to log micro-stops, while our AI groups the data to reveal your most expensive bottlenecks so you can finally fix them.
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Your ERP and MES only catch major downtime events. But those 60-second machine jams that happen 40 times a shift? They add up to hours of lost capacity that never make it to 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 trying to speed up a cycle time when the real issue is constant minor stoppages.
1-Click Capture
Operators log a micro-stop in two seconds without leaving their station.
AI-Driven Aggregation
The system automatically groups hundreds of minor stops into massive, quantifiable financial losses.
Targeted Elimination
Data feeds directly into Kaizen workflows to permanently engineer out the nuisance stops.
Issue Management captures every minor stop at the moment it occurs with category, duration, and contributing factor logged instantly. Asset Management builds the financial loss tree by aggregating stop data into equipment-level cost totals. Kaizen and Projects converts the highest-frequency loss patterns directly into improvement project launche
Daily Issue Management
Real-Time Micro-Stop Capture
We replace paper tally marks. Operators use a tablet equipped with large, customized buttons to instantly log a misfeed, sensor fault, or minor jam the moment it happens.
Replace paper tally marks with digital logging
Large, customized tablet buttons for instant capture
Log misfeeds, sensor faults, and minor jams in real-time
Capture micro-stops the moment they occur on the line
Loss & Cost Management
Financial Impact Visibility
Leansuite aggregates these micro-stops, calculates the lost cycle time, and attaches a dollar value to the downtime, building a live Pareto chart of your biggest hidden losses.
Aggregate all micro-stops across lines and shifts
Calculate lost cycle time and financial impact automatically
Generate live Pareto charts of hidden losses
Reveal the true cost of minor stops with data-driven visibility
Kaizen & Projects
Targeted Improvement Initiatives
Now that the invisible is visible, your CI and Engineering teams can launch targeted Kaizen events to redesign the faulty sensor or misaligned guide rail that is causing the interruptions.
Launch targeted Kaizen events based on data-driven insights
Focus CI and Engineering resources on highest-impact issues
Redesign faulty components causing chronic interruptions
Eliminate root causes permanently, not just symptoms
OEE Optimization
When you are sold out of capacity, buying a new production line is a multi-million dollar gamble. Eradicating your micro-stops can unlock 10% to 15% more capacity from the equipment you already own.
Fix the Performance Metric
OEE is calculated by Availability × Performance × Quality. Micro-stops silently kill your Performance metric. Leansuite exposes the exact reasons why a machine isn't running at its theoretical maximum speed.
Operator Empowerment
Give your operators the tool to finally prove to management how frustrating and frequent these "minor" interruptions actually are.
66% OEE
Before Implementation
79% OEE
After Implementation
High-Speed Manufacturing
In continuous manufacturing, packaging, and high-speed assembly, seconds matter. We built Leansuite's interface to be lightning-fast. We know that if logging a stop takes longer than clearing the jam itself, the operator simply won't do it. Our UI is designed by manufacturing veterans to ensure 100% adoption on the fastest lines in the world.
SOC 2 Type II Certified
20+ Years Lean Expertise
Global Deployments
99.95% Uptime SLA
