The Challenge
Industrial manufacturing plants face constant hurdles with stock-outs of critical raw materials, untracked shop-floor bottlenecks, scrap inflation, and inaccurate unit manufacturing costs. ForgeFlow was developed to give plant managers and floor supervisors total end-to-end visibility. It automates multi-tier Bill of Materials (BOM) explosions, generates shop-floor job cards, tracks Work-In-Progress (WIP) across machine workstations, monitors quality rejection rates, and tracks Overall Equipment Effectiveness (OEE).
What We Built
Every feature was crafted to solve a real problem and deliver measurable value to the business.
Multi-Level Bill of Materials (BOM)
Configure finished product assemblies, sub-assemblies, raw material quantities, and scrap allowances with version control
Production Planning & Master Scheduling (MPS)
Forecast production capacities, machine runtimes, and allocate work orders against customer sales demand
Material Requirements Planning (MRP)
Automatically calculate raw material requirements to prevent line stoppages and over-purchasing
Work Orders & Stage Routing
Issue production work orders with predefined routing steps: machining, fabrication, welding, coating, and assembly
Shop Floor Job Cards & Operator Logging
Floor supervisors allocate tasks to machines and operators, logging output quantities, cycle times, and scrap
Live Work-in-Progress (WIP) Tracking
Monitor parts flowing through assembly lines with real-time bottleneck identification
In-Process & Final Quality Assurance
Defect classification, tolerance inspection, rejection logs, and quarantine holding workflows
Raw Material & Finished Goods Inventory
Bin-level warehouse tracking with automated Goods Receipt Notes (GRN) and material issue vouchers
Machine Maintenance & OEE Monitoring
Preventive maintenance scheduling, breakdown logging, machine downtime analysis, and equipment efficiency
Batch Costing & Profit Margin Analysis
Computes true unit production cost by combining raw materials, direct labor, and machine hour electricity overheads
Our Process
We started with a deep discovery phase to understand the core business goals of ForgeFlow — Manufacturing & Production Management ERP. Following an agile methodology, we moved from wireframes to full-stack development, rigorous testing, and a seamless deployment — with continuous feedback loops ensuring every decision served the end user.
The Outcome
ForgeFlow — Manufacturing & Production Management ERP was delivered as a high-performance, production-ready product — built to scale, easy to maintain, and designed to create real business impact from day one.