1. Tag it on the spot
Scan the QR code on a machine to see its open tags and add to one, or raise a new tag: snap a photo, pick a category such as Safety or Quality, and type or speak a note.
Daily Issue Management: Solve shop floor problems, instantly
LeanSuite's daily issue management software (the F-Tag module) lets anyone on the floor tag a problem in seconds, sends it to an owner with a due date, and tracks it until it's fixed.
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HOW IT WORKS
Bring structure to shop floor problem-solving
Capture, track, and resolve every issue in three steps.
2. Track it in real-time
Each tag appears on the live dashboard and floor plan straight away, and its owner gets an in-app, email or push notification.
3. Resolve it with accountability
Due dates follow priority, reminders go out before and after a deadline, and each fix waits in Pending Verification before the tag closes.
AI AND VISUALIZATION
See where issues happen, and why
Live floor plan mapping and Lean AI show what's happening on your floor, where, and why, in real time.
FLOOR PLAN VISUALIZATION
See where problems cluster on your floor
Your facility layout becomes a live map of open tags, with a heat map of hotspots. Tap an area to raise a tag there, or put the map on a shop-floor TV.
LEAN AI IMAGE RECOGNITION
Let Lean AI be your eyes on the floor
Operators snap a photo and Lean AI writes a detailed description of the problem, so every issue is logged in the same clear way.
AUTOMATION
Automation that keeps every issue owned
Rules route each issue, set its deadline, and stop it bouncing between people.
Auto-assignment
Rules route each issue to the right person by tag type, area, department and priority.
Auto due dates
Set due dates automatically from priority, so urgent issues are handled first.
Reassignment tracking
Cap how many times an issue can be reassigned, so it can't bounce around.
MORE IN F-TAG
Built for how the shop floor actually works
The details frontline teams and supervisors ask for most.
- See how it works about QR codes that stop duplicates
QR codes that stop duplicates
Scanning a machine's QR code shows its open tags, so people add to one instead of raising the same issue twice. You can print tags for physical boards too.
Speak instead of typing
Operators can dictate a tag in the mobile app instead of typing it.
- See how it works about Kanban board and saved views
Kanban board and saved views
Drag tags between statuses on a Kanban board, or save a filter as a view you can pin and share with your team.
Floor plan on a shop-floor TV
Show the full-screen floor plan on a TV. It refreshes itself, so open tags stay current all shift.
- See how it works about Tier escalation
Tier escalation
Escalate a tag from tier 1 to tier 2 or 3, or send it back down, with its history attached. Each tier works from its own saved-view queue.
- See how it works about Built-in reports
Built-in reports
See opened vs closed trends, hot spots by area, cost by asset and tags per person.
- See how it works about Your tag types and fields
Your tag types and fields
Set your own tag types, colors, priorities, issues, sub-issues and trade types, and choose which form fields are shown, renamed or required.
- See how it works about Employee-ID sign-in
Employee-ID sign-in
Operators log in with an employee ID or username on the app or a shared tablet. No email address needed.
- See how it works about Notifications and reminders
Notifications and reminders
In-app, email and push notifications tell owners about new tags, coming deadlines and overdue work.
AI next steps
Lean AI reads a tag's photos, attachments and comments and summarizes the next steps for its owner.
- Corrective action log about Replace the paper action sheet
Replace the paper action sheet
Use tags as your corrective action log: one list of issues with owners and due dates in place of the sheet on the production board.
- See how it works about Clone a tag
Clone a tag
Copy an existing tag to raise a similar issue without filling in the form again.
ISSUE TAGS
A tag for every type of shop floor issue
Sort every issue by type for cleaner tracking, and create custom tags for any process or department.
Safety tags
Capture unsafe acts and conditions the moment they're spotted.
Learn MoreQuality tags
Flag defects, non-conformances, and other quality deviations.
Learn MoreAutonomous Maintenance tags
Let operators tag contamination sources and hard-to-access areas on their equipment.
Learn MoreProfessional Maintenance tags
Flag machine faults, leaks, and other repairs for the maintenance team.
Learn MoreEnvironment tags
Report spills, waste, or other environmental concerns.
Learn More
A CONNECTED SYSTEM
Turn daily issues into long-term improvements
Daily issues feed straight into your wider continuous improvement work.
Escalate to Kaizen
Same issue again? Escalate a recurring problem into a Kaizen or A3 project in one click and fix the root cause.
Tie tags to work orders
A tag can carry the work-order number from your maintenance system, so the two records stay linked.
Analyze trends
Break issue data down by line, shift, or problem type to find your biggest opportunities for improvement.
EMERGENCY WORK ORDERS (EWO)
Log every breakdown as an EWO
An emergency work order records a breakdown or incident from start to fix: downtime and MTTR are worked out, the repair and parts are logged, and the root cause can become a Kaizen.
- What is an EWO? about Downtime and MTTR
Downtime and MTTR
Enter when the breakdown started and ended. Downtime and MTTR are calculated, with repair time split into waiting, diagnosis and parts time.
Repair and parts used
Record what was repaired and which spare parts were used on each breakdown.
Root cause and failure curve
Classify each breakdown by root-cause category and spot repeat failures with failure curve analysis.
- AI root cause analysis about AI root cause drafts
AI root cause drafts
The AI RCA agent drafts the 5 Whys and 4M1D from the description and any attached manuals or SOPs. You edit it.
- See how it works about Your own workflow
Your own workflow
Set the EWO's stages, and at each one who can move it, what must be valid first, what updates on its own when the status changes and who is told.
Convert to a Kaizen
When a breakdown needs a lasting fix, convert the EWO into a Kaizen project.
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.
What customers say
“Great user-friendly software! It's covering everything that WCM or similar Lean Programs are asking to do, in a very effective way.”
Elena M.Global Head of Marelli Manufacturing System Automotive, Marelli“Customer support has been exceptional. The team is always available to answer questions and consistently provides prompt responses. I have been working closely with them to set up KPIs and time studies for our company, and their level of support throughout the process has been outstanding”
Luis R.CI Engineer, Tomball Controls“The Project Tracking System generates significant savings while ensuring seamless delivery... The Global Kaizen Power Pitch completely transformed our ability to share best practices.”
Ramsey AljahmiSr. Director of NAR Operations Excellence, Whirlpool Corporation
FAQs
Frequently Asked Questions
Daily issue management software gives frontline teams one place to report shop floor problems and track each one until it is fixed. In LeanSuite this is the F-Tag module: operators raise a tag from a QR code, and it lands on a live dashboard with an owner and a due date.
Abnormality tagging is the lean and TPM practice of marking a problem where it is found, traditionally with a colored card hung on the machine, so it stays visible until it is fixed. LeanSuite replaces the cards with digital tags that each have an owner, a due date and a place on the live floor plan.
They scan the QR code at the machine, check whether the problem is already tagged, then snap a photo, pick a category and type or speak a note. Lean AI can write the description from the photo. Operators sign in with an employee ID on the mobile app or a shared tablet, so no email is needed.
Rules assign each tag by tag type, area, department and priority, and set its due date from priority. A tag that can't be fixed locally is escalated to tier 2 or tier 3 with its history, and can be sent back down with a decision. You can also cap how many times a tag is reassigned.
LeanSuite has tags for safety, quality, autonomous maintenance, professional maintenance and environmental issues. You can also create custom tag types for any process or department.
An emergency work order (EWO) records a breakdown or incident: when it started and ended, the downtime and MTTR, the repair, the parts used and the root cause. It follows a workflow built to your plant's own steps, with rules for who can move it, what must be valid first, what updates on its own and who is told, and it can be converted into a Kaizen with its details and photos carried across.
No. LeanSuite isn't a CMMS and works alongside yours. A tag can carry the work-order number from your maintenance system, so the two records stay linked, and breakdowns are logged as EWOs with their downtime and root cause.
Escalate it into a Kaizen or A3 project in one click and work on the root cause. Tag reports show which areas and assets keep generating issues.
FREE RESOURCES
Free templates and tools
Not ready for software yet? Start with these free resources.
- 5 Whys templateA problem statement, a why chain that can branch, evidence for every answer, root causes and countermeasures that are checked.
- Gemba walk checklistA walk plan and route, 30 prompts in six groups and a findings table with owners and due dates.
- Material shortage logEvery part short with its need date, line impact, ETA and escalation, and counts by reason and supplier.
- Andon response logEvery andon call with response and fix times, flags against your targets, and counts by type and station.
- Escalation matrix templateWho is called for each type of issue and after how long, with severity rules, contacts and an escalation log.
- 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.
- Jidoka worksheet (stop at abnormality)For one line or cell, every abnormality that should stop the work: how it is detected, how the work stops, who is called, the immediate fix and the root cause step, plus a log of real stops.
- Professional maintenance (PM) 90-day model area planThirteen weeks from breakdown analysis to a running PM calendar on one model machine, a KPI board, the day-90 gate and expansion waves.
- Downtime cost calculatorWhat an hour, an event and a year of unplanned downtime cost, from lost output, idle labour, scrap and overtime.
Ready to solve problems for good?
See how LeanSuite helps you build a more proactive operation, one solved issue at a time.