Get to know LeanOS, at your own pace.
Eleven short films, about 23 min in all, set in one real plant and covering every module. Start wherever is most useful to you. Whenever you would like to talk it through, we would be glad to.
Root Cause, in LeanOS.
Last time, the spill in the packing aisle was found, planned and fixed. But a fix on the floor isn't a fix in the system. What stops it coming back?
A fixed defect can go three ways. Promote it to a kaizen, write a one-point lesson, or open a root cause, because what you fixed may only be the symptom.
Root cause used to mean a blank A3, a room full of experts, and days of meetings before anyone wrote down a single cause.
LeanOS changes that. The A3 starts already filled in. AI gives the team a head start. And people still make every call.
Open the root cause, and everything the defect already knows comes with it: the photo, the problem, the zone and the link back. Quality NCRs and safety incidents link in the same way.
Paste the customer's complaint, and AI drafts why it matters and what good looks like. Then name a lead, a zone and a target date.
Then the fishbone. One tap on Suggest with AI, and real causes land on all six bones: people, equipment, method, materials, measurement and environment.
But nothing is automatic. Your team confirms each cause with a test, or rules it out. AI proposes; people decide.
Now drill into the cause that matters. AI drafts each why, so the team stays on one thread instead of drifting. Branch when there's more than one, and mark the root cause.
For the root cause, AI suggests countermeasures. Use one, give it an owner and a date, and nothing slips.
What used to take weeks of meetings now fits in a single working session. The thinking stays human. The speed comes from AI.
Then prove it worked. Record the check: six spills a week before, zero after, against a target of zero. And a case only closes when someone else verifies it.
Update the standard, write down what the plant learned, and turn it into a one-point lesson for every shift.
And it all lands on one page: a clean A3 report with your company's logo on it, ready to print. Send it to a customer, a supplier or an auditor, as proof it's fixed for good.
Root Cause in LeanOS. Next: Improvements.
Root Cause
An A3 filled in from what you already logged, then a report with your logo.