Analysis 01

Time & Motion Study

AI watches every cycle and automatically classifies each motion as value-add, non-value-add, or pure waste. Get cycle time distributions, element-level breakdowns, and workstation optimization recommendations without a single stopwatch reading.

  • Per-element timing with statistical variance

  • Auto-detected waste categories (TIMWOODS)

  • Operator vs. machine time separation

Time and motion study element breakdown dashboard

Analysis 02

Digital Work Instructions

From a single video, Leansuite extracts each discrete step, captures the exact frame, and assembles a fully illustrated work instruction. Tribal knowledge becomes documented, repeatable standard work in minutes.

  • Auto-numbered steps with embedded screen captures

  • Multi-language translation built in

  • Operators acknowledge & sign off in-app

Digital work instructions with compliance sign-off

Analysis 03

Line Balancing & Yamazumi

Compare every station's cycle time against takt, identify your bottleneck, and let AI suggest task reallocation to flatten the Yamazumi. Test scenarios virtually before changing a single layout.

  • Side-by-side current vs. future state

  • What-if rebalancing simulator

  • Quantified labor productivity gain

Time and motion study element breakdown dashboard

Analysis 04

Value Stream Mapping

Walk your facility once with a phone, and Leansuite stitches the footage into a complete current-state VSM — process times, wait times, inventory levels, and information flow all captured automatically.

  • Process & lead time ratio calculated

  • Inventory triangles auto-quantified

  • AI-recommended future-state map

Time and motion study element breakdown dashboard

Analysis 05

Ergonomic Study (REBA / RULA)

Pose-estimation AI scores every frame for postural risk using validated REBA and RULA methodology. Pinpoint the exact tasks driving injury exposure and prioritize corrective actions before claims happen.

  • Body-region heatmap (neck, back, shoulder, wrist)

  • Risk severity by task element

  • Recommended jig/fixture countermeasures

Time and motion study element breakdown dashboard

Analysis 06

SMED — Quick Changeover

Film a changeover once. AI segments every task, classifies internal vs. external setup, and proposes the conversion sequence that gets you closest to single-minute exchange of die.

  • Automatic internal/external classification

  • Parallelization opportunities flagged

  • Target vs. baseline changeover time

Time and motion study element breakdown dashboard

Standard Operating Procedures (SOPs)

AI converts your video into a fully structured SOP — including purpose, scope, responsibilities, step-by-step tasks, safety notes, and embedded screen captures from the source footage.

  • Auto-numbered steps

  • Embedded photo evidence

  • Revision control & e-signatures

Standard Maintenance Procedures (SMPs)

Generate maintenance procedures from a single technician walkthrough video. Capture torque values, lockout points, tools required, and PPE — all timestamped to the original footage.

  • LOTO checkpoints

  • Tools & parts BOM

  • Frequency & duration estimates

One-Point Lessons (OPLs)

Distill a 20-minute video into a single, visual one-page lesson operators can absorb in 60 seconds. Perfect for tribal knowledge transfer and shift handovers.

  • Single-page format

  • Before/after visuals

  • QR-linked back to source video

AI analysis visualization

Why It Matters

Compress Weeks of IE Work Into Hours

A traditional time study requires industrial engineers to manually stopwatch every element, transcribe data into spreadsheets, and build deliverables by hand. Leansuite eliminates 90% of that effort by letting AI watch the video for you — frame by frame, element by element.

10x Faster Studies

What took a senior IE 2 weeks now takes an afternoon — freeing your team for actual improvement work.

Zero Observer Bias

AI measures every cycle objectively. No Hawthorne effect, no rounded numbers, no missed micro-stops.

Permanent Visual Record

Every output links back to the exact source frame. Auditors, trainers, and operators can verify any claim instantly.