How Manufacturers Use ForgeOS
From steel mills to precision machine builders to high-volume appliance lines—ForgeOS adapts to your operation, not the other way around.
They bought during the demo.
During a 30-minute demo, we asked a steel manufacturer what they wished their MES could do. They described a custom operator entry screen for tracking heat treatment batches—something their current vendor had quoted at 6 months and $180K. We built it. Live. In 15 minutes. Then they asked about a production report they'd been requesting for two years. We built that too. They purchased ForgeOS before the call ended.
What They Got:
15 min
Feature build time
$0
Development cost
Same day
Purchase decision
"Our vendor quoted 6 months and $200K. You did it in 30 minutes. What else can it do?"
Quality screens in 22 minutes. Compliance confidence in weeks.
Automotive Tier 1 suppliers live and die by compliance. IATF 16949 audits. PPAP documentation. Defect tracking that can trace a problem back to its source in minutes, not days. But when every quality screen requires a 4-month project and $180K budget, you make do with spreadsheets and workarounds. Until the auditor arrives.
ForgeOS Changes the Math:
22 min
Quality screen build time
100%
Audit-ready documentation
4 months
Saved vs. quoted time
"Our MES vendor quoted 4 months and $180K for custom quality screens. ForgeOS built them during the demo."
Every unit is different. Finally, an MES that gets that.
Building $500K CNC machining centers isn't like assembly line manufacturing. Every unit has engineering changes mid-build. Serial-tracked components get swapped during test. And when a spindle comes back for rebuild 3 years later, you need to know exactly what's in it—not what the BOM said should be in it. Standard MES platforms are designed for repetitive manufacturing. Every deviation requires a workaround. Every field return becomes a spreadsheet nightmare.
ForgeOS Pattern MES:
3 days → 4h
Field return processing
100%
As-built accuracy
6 weeks
Deployment vs. 14 mo. quoted
"We build 200 machines a year, each one different. Every MES vendor told us we were 'too custom.' ForgeOS just asked us to describe our process."
15 models per shift. One MES that keeps up.
Modern appliance manufacturing runs dozens of SKUs down the same line. A refrigerator line might switch between 15 models per shift—different components, different torque specs, different quality checks. Traditional MES requires weeks of configuration for each new model. Work instructions live in binders that are always outdated. Quality data exists but takes days to analyze. By the time you've got the reports, the problem has already shipped.
ForgeOS for High-Mix:
2 days → 3h
New model setup time
15 min
Work instr. updates (was 2 wks)
$0
Custom report cost (was $40K)
"We used to pay our MES vendor $40K every time we needed a new report. Now our engineers build them during their morning coffee."
Ready to see ForgeOS handle YOUR operation?
Every manufacturer thinks they're too custom, too complex, too different. Show us your hardest problem.
Background & Experience: Our team has deployed industrial technology at manufacturers including Bühler, B/S/H Home Appliances, and aerospace OEMs. We've seen what works—and what doesn't—across shop floors worldwide.