Your best operator can’t be at every station.

So their method goes there instead. The current revision at every station, the work checked as it happens, and a record of what was actually built. Live on one line in six weeks.

Start a Launch Pilot · $2,500 Book the live build

Already running a system of record?

A whiteboard showing a tool and die process drawn end to end in green marker, with the quality gates circled in blue over the top. — Eight operations. Three quality gates. Two approvals.

Step 02 of 07Conditions

You know how this plant should run. Getting it to run that way every shift is the hard part.

The real process is on a whiteboard in the quality office, in a binder one revision behind, and in the heads of a few people you can’t afford to lose. New hires shadow for weeks. Checks go on a clipboard and get typed in on Friday. When something escapes, you rebuild what happened from memory.

And when your best operator calls out, you hold your breath.

Step 03 of 07Root cause

It isn’t your people. It’s tools built from the office down.

Most plant software is designed for the people who read the reports, then handed to the people who build the product. Operators work around screens that weren’t made for gloves, noise, or takt time. So the plant drifts back to paper, projects run twelve to eighteen months, and every change means retraining.

Doing it right shouldn’t depend on who is on shift.

Step 04 of 07Who's on the other end

We’ve stood at that whiteboard.

Our founder has spent 27 years on plant floors, from Toyota Production System lines to automotive Tier 1 and aerospace. Before ForgeOS, our team deployed connected-worker systems in seven plants across automotive, appliance, industrial, and logistics. We learned what operators actually use and what they quietly stop using. ForgeOS Method is built from that.

BSH
Bühler
BMW North America
DHL Supply Chain
Unipres

2024 finalist, Technology Development, South Carolina InnoVision Awards.

Step 05 of 07Procedure

Three steps. Six weeks.

1
Start the pilot.
$2,500, one payment, no subscription. Tell us which line and when it launches, and we come back with dates. Includes six weeks on one line, up to ten work instructions authored with your team, and two RealWear HMT-1 headsets.
2
Send us what exists.
A whiteboard, a binder, or a phone video of the job. Your engineer sends it, and we build the instructions with your team.
3
Keep it running.
$1,000 a month or $12,000 a year (includes two headsets). Unlimited users, unlimited instructions, no per-seat math. Additional headsets $397.

Needed to continue

Start a Launch Pilot · $2,500

One fixed price. Tell us your line and your launch week and we come back with dates.

Hold If nothing changes

The process walks out the door with whoever knows it.

The veteran retires. The escape reaches the customer before anyone at the station catches it. The audit becomes a week in the filing cabinet. None of it shows up on a report until it’s already expensive.

Step 06 of 07Record

What the plant looks like after.

Instruct
A new hire runs the job correctly on day two.
The job video, annotated at the exact moment it matters, with captions.
Capture
Quality data is captured at the station, not typed in on Friday.
Measured at the station, checked against spec the moment it is entered.
Enforce
A failed check stops the job and logs a deviation, which routes to a nonconformance.
The check has no soft answer.
Fail it and the system asks for the deviation.
Record
Traceability is a query, not a filing cabinet.
Task complete, Recorded, and the next task is already waiting.
Adapt
The sequence changes when the part changes.
Assist
When the instruction runs out, an expert is one tap away.

And you stop being the one who holds it all together.

Step 07 of 07Branch

Not every plant starts in the same place.

Keep Rockwell, Siemens, or SAP where they are. ForgeOS connects to what you run.

See it built live

On a fifteen minute call, tell us a feature you need and we build it while you watch. Not a mockup. A working feature running on the platform. If we cannot, we do not ask for a next step.

Book the live build