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ENTERPRISE · ERP

Forgeline Manufacturing Suite

Next-Gen Plant Operations & Closed-Loop Quality Telemetry

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Client / Purpose
Helix Heavy Industries
Status
Active Sandbox
Technologies Used
Next.jsTypeScriptTailwind CSSRechartsLucide Icons

Live Recording & Interactive Gallery

forgeline-manufacturing-suite.vercel.app/plantDEMO_WALKTHROUGH (AUTOPLAYING)
Forgeline Manufacturing Suite Preview
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Forgeline Manufacturing Suite Preview Screenshot 1
Forgeline Manufacturing Suite Preview Screenshot 2
Forgeline Manufacturing Suite Preview Screenshot 3

Project History & Context

Forgeline Manufacturing Suite was engineered in partnership with heavy industrial casting and forging operators to centralize floor operations. Traditional ERPs isolate quality controls from preventative maintenance and material availability logs. Forgeline links these domains, allowing supervisors, quality inspectors, and maintenance crews to collaborate in real-time.

Interactive Sandbox:All screens and video previews are compiled directly from the live testing instances running on AhiXLight edge servers.
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Core capabilities & interface details

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Plant Command Cockpit
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Plant Command Cockpit

The primary control cockpit summarizing overall equipment effectiveness, material shortage indicators, and shopfloor work centers.

  • ▪OEE indicator dials tracking plant-level availability and yield in real-time.
  • ▪Dynamic material shortage listings flagging raw materials supply issues.
  • ▪Fuzzy query fields filtering shopfloor statuses by machine center.
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Production Shift Supervisor Panel
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Production Shift Supervisor Panel

A scheduler workspace tracking active work order targets, shift parameters, and hourly output rates.

  • ▪Work order schedules detailing active operators and job runs.
  • ▪Hourly output rate charts analyzing production yield against targets.
  • ▪Instant submission forms recording shift status summaries.
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Statistical Quality Inspector Dashboard
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Statistical Quality Inspector Dashboard

A quality tracking control panel auditing defect rates, SPC controls, and non-conformance reports.

  • ▪SPC control charts plotting defect rates against upper and lower thresholds.
  • ▪First pass yield summaries broken down by shifts.
  • ▪Review triggers submitting quality audits directly to plant managers.
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Asset Maintenance Ledger
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Asset Maintenance Ledger

A preventative maintenance timeline scheduling active tasks, downtime logs, and Pareto statistics.

  • ▪Downtime Pareto charts detailing root causes of equipment failures.
  • ▪Priority work order lists sorting tickets by downtime impact risks.
  • ▪Equipment rosters logging maintenance history per asset category.

The Architectural Problem

Heavy manufacturing operations suffer from communication silos between management, supervisors, quality inspectors, and maintenance technicians, causing delayed downtime responses and high defect rates.

The Implemented Solution

Forgeline integrates plant operations telemetry, supervisor shift logs, statistical process control, and preventative maintenance tasks into a unified, high-performance command workspace.

Functional Specifications

  • [01]

    Plant-level OEE monitoring panels aggregating yield and availability metrics.

  • [02]

    Production scheduling interface tracking job batches across active work shifts.

  • [03]

    Closed-loop Quality SPC control limits monitoring defect rates dynamically.

  • [04]

    Predictive Maintenance backlog management sorting active tickets by equipment downtime risk.

Systems Architecture

Plant Dashboard: Consolidated executive cockpit parsing OEE, schedule milestones, and raw telemetry.

Quality Control limits: Real-time SPC algorithm plotting first-pass yield and defect alerts.

Maintenance backlog: Asset registry tracking downtime logs and scheduling preventative tasks.

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