Manufacturing Execution
Industry Software

Forge Manufacturing Execution

Bridge the gap between ERP planning and the factory floor. Forge turns sales orders into production plans, tracks every material movement, and enforces quality at every step.

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End-to-End SO to Shipment From sales order to production plan to finished goods shipment in one system
Real-time Shop Floor Tracking Operator time entries, material issues, and quality checks as they happen
Integrated ERP Sync Stock movements, BOMs, and purchase orders sync with COSAP automatically
The Scenario
Your production floor just received a sales order for 2,000 units. Somewhere between the BOM, the warehouse, and the shop floor — materials run short, quality gets missed, and variances go unnoticed until it's too late. Forge connects every step. From sales order to shipment — every job tracked, every material accounted for, every quality gate enforced.
Most MES tools sit beside your ERP. Forge shares inventory, BOMs, vendors, and finance with COSAP. No sync jobs, no data duplication, no integration middleware.
The Concept
"Not another ERP module. Execution software that lives on the factory floor -- where plans meet reality and variances are caught, not discovered."
Traditional MES Forge
Separate system from ERP Built on COSAP -- shared inventory, BOMs, and finance
Manual production scheduling Auto-generate plans from sales orders
Paper-based shop floor logs Digital job tracking with operator time entries
Quality checked after the fact Inline QC with hold gates and defect logging
Procurement is a separate workflow Auto-PRs on shortage, PO conversion in one click
The Production Chain

Every job traces to a sales order. Every material issue traces to a BOM. Nothing is unaccounted for.

01 Sales Order ›
02 Plan ›
03 Job ›
04 QC ›
05 Ship
Capabilities

Core capabilities

Covering the full manufacturing lifecycle from order intake to outbound shipment.

Production Planning
Generate production plans directly from sales orders. Break plans into jobs, assign operators, and track progress against targets with real-time time entries.
Sales Order → Plan → Jobs → Track
  • Auto-generate plans from SO line items
  • Operator job assignment and time tracking
  • Configurable production sub-phases
BOM & Material Management
Multi-level bill of materials with material issue, backflush, and return workflows. Stock movements sync directly with COSAP inventory in real time.
BOM → Issue → Consume → Return
  • Multi-location split picking
  • Dual sign-off on material movements
  • Auto-PR generation on material shortage
Quality Control
Inline quality inspections with configurable test parameters, pass/fail tracking, defect logging, and QA release gating. Nothing ships without sign-off.
  • Parameter-level test entry with pass/fail per line
  • Quarantine hold with QA release blocking
  • Defect logging with root cause classification
  • AI-powered compliance scanning
Warehouse & Location Management
Multi-location stock tracking with capacity enforcement, FIFO validation, hazmat limits, safety stock monitoring, and lot age tracking across all storage zones.
  • Capacity and hazmat limit enforcement
  • FIFO and lot expiry management
  • Location assignment on receipt
  • Safety stock alerts and auto-reorder
Purchase Requests & Procurement
Auto-generate purchase requests from material shortages. Route through approvals, convert to purchase orders, and track through goods receipt -- all in one system.
Shortage → PR → Approve → PO → GRN
  • Auto-PR on low stock or BOM shortage
  • One-click PR to PO conversion
  • GRN with location assignment
Monitoring & Alerts
Proactive alerts for capacity thresholds, safety stock, lot expiry, fire permit deadlines, OEE deviation, and compliance deadlines. Delivered via Telegram, email, or in-app.
  • Capacity threshold and safety stock alerts
  • Lot age and dwell time warnings
  • OEE and yield deviation detection
  • Severity-based routing and daily digests
Operator Surface

From alert to action: One tap inside the closed loop.

Four principles that get adoption on day one — no training required.

🧤
Field-First UI
Big buttons, two-tap. Works with gloves, dust, and noise.
🤖
Two-Way AI Feedback
AI verdict, reason, and quantity are inside the message — not in a separate report.
📋
Workflow Native
The Push message IS the work order. No paper detour, no desktop login.
👷
Operator-Centered
Button label is the instruction. Zero training required.
9:41
Forge Tasks 2
URGENT
Ghost PO detected
Vendor A · Item X · 50 units
WARN
BOM deviation alert
Line 3 · Material Y · +12%
🤖 AI Assessment: Input quantity exceeds recipe tolerance by 12%. Suggest hold and re-weigh before proceeding.
DONE
Stock count complete
Bin A7-5 · 240 kg verified
✅
All clear
Forge is watching
AI Safety Net

Five patterns. All leaking money.

Each is a different shape of loss — and a different signal only AI can catch in real time.

Ghost PO
A purchase order that exists on paper but never matched a real goods receipt. Vendor invoices it anyway.
BOM Deviation
Actual material consumption drifts from the bill of materials recipe — silently inflating cost per unit.
Expired Stock
Lots past expiry date picked and consumed in production — FEFO violation, compliance risk, and scrap cost.
Phantom Inventory
System-recorded stock that doesn't physically exist. Causes MRP failures and surprise shortages mid-run.
Duplicate Billing
Vendor invoices submitted twice under different reference numbers. Fingerprint match catches it at submission.
Before & After Forge
Ghost PO~14 days post-audit→< 1 day auto-hold
BOM DriftMonthly reconciliation→3-day rolling alert
Expired StockManual scan→Pick-time auto-block
Phantom InventoryQuarterly 3-day audit→Daily targeted partial
Duplicate BillingMostly missed→All flagged at submission
Integration

Built on COSAP,
not bolted on

Forge shares inventory, BOMs, vendors, and finance with COSAP. No sync jobs, no data duplication, no integration middleware.

Shared inventory
Material issues and finished goods receipt update COSAP stock levels in real time. One source of truth for all warehouse operations.
BOM from COSAP
Read BOMs and product catalogs from COSAP. When production consumes materials, stock levels reflect across both systems immediately.
Procurement pipeline
Purchase requests convert to COSAP purchase orders. Vendors, pricing, and delivery terms flow through the existing procurement chain.
Sales order automation
Sales orders from COSAP automatically trigger production plans. Shipped quantities update SO line items. No manual data entry.
Stock In
WO complete: +500kg HDPE pipe
Finished goods auto-stocked to warehouse. COSAP inventory updated.
Stock Out
Material issue: -200kg CACO3
Raw material consumed from Zone A7-5. Stock level synced to COSAP.
Auto PR
Shortage detected: Stabilizer
BOM requires 50kg, only 12kg on hand. Purchase request auto-generated.
GRN
Goods received: PO-2026-0042
Vendor delivery confirmed. Stock in to Quarantine pending QA release.
Workflow

Order to shipment
in four steps

From incoming sales order to outbound shipment. Every step tracked, every movement recorded, every variance captured.

01
Plan & Schedule
Sales orders generate production plans. BOMs determine material requirements. Shortages trigger automatic purchase requests.
02
Execute & Track
Operators pick up jobs, log time entries, issue materials from warehouse. Every action timestamped and attributed.
03
Inspect & Release
Quality inspections at configured checkpoints. Test parameters measured, defects logged. QA release gates prevent shipping uninspected goods.
04
Ship & Reconcile
Finished goods stocked to warehouse. Shipments created from completed work orders. SO line quantities updated. Variance analysis available.
Impact

Snapshot by The Numbers.

82%
PO errors auto-blocked
12.4 → 2.1 per month
94%
On-time delivery rate
Up from 73% baseline
67%
Late delivery reduction
From 27% → 6% miss rate
23 min
AI detection response
From 14.3 days post-facto
Customer Story

"We use Forge across all three of our plants. It helps us catch procurement errors before they become losses, keep our lines on schedule, and give our managers real visibility into what's happening on the floor."

W
Country Manager, WAPS Vietnam
Polymer & Construction Materials
Binh Duong, Vietnam
LIVE
ARIZE — main polymer plant
54,000 m² land · 24,000 m² plant
Cheongju, Korea
LIVE
WAPS — polymer & construction materials
14,180 m² land · 5,400 m² factory
Yangsan, Korea
LIVE
WAPS — head office & polymer materials
3,776 m² land · 1,400 m² factory
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