Three kinds of phone calls turn a manufacturing CEO grey: the recall call, the warranty-claim spike, and the customer auditor showing up unannounced. All three ask the same question: "what did you build, with what, by who, when, and how do you know?" Ignite Lean answers them in three clicks because the answer was captured automatically at build commit, not reconstructed from sticky notes.
When the operator hits "commit" on the last step of a build, Ignite Lean writes one immutable build record: the operator (by name + user id), the workstation, the start and finish timestamps, every component consumed (by part number and lot/serial), every parent serial scanned, every photo taken in-line, every defect flag raised, every supervisor approval. The record is append-only. Corrections are new events, not overwrites. So the auditor can trust that what they see is what happened.
A vehicle (BC-260517-0023) is built from a left-front caliper sub-assembly (CA-26051-0019), which was built from a rotor (R-260517-091), a set of pads (P-260517-204), and a kit of fasteners (lot F-26044-12). Ignite Lean captures the parent-child relationships at the join station. The operator scans the caliper serial when assembling the brake corner, and the merge is recorded automatically. Pull BC-260517-0023 later and you get the full tree, exactly as built.
Tuesday at 3:14 p.m., a customer reports brake-pad delamination on BC-260517-0023. You suspect the pad supplier sent a bad lot. Open the build record, see lot P-260517-204 on the affected unit, then reverse- lookup: every unit that consumed lot P-260517-204. 47 units. Three already shipped, 12 in finished-goods, 32 still in progress. Without Ignite Lean: a week of sticky-notes and supervisor memory, with a good chance of missing units. With Ignite Lean: one click.
BC-260517-0023BC-260517-0023CA-26051-0019R-260517-091 · lot R-26049-2 P-260517-204 · lot P-26049-7 The build history page lists every build the org has ever done. Filter by date, operator, workstation, status (pass / fail / on-hold), serial prefix, or product. Tap any row for the full record. Every step, every consumed part, every photo, every approval. The auditor sits down, asks "show me 20 random units from last quarter", you set the filter, they sample. Ten minutes vs. half a day with binders.
The single most important property of an audit log is that nobody can change it after the fact. Including the admin. Ignite Lean enforces this at the database level: build events are insert-only, with no update or delete privileges granted to any application role. A correction is a new event ("operator reflagged unit BC-260517-0023 as scrap, original pass-flag preserved"), not an overwrite. The auditor reads the timeline, not a rewritten version.
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