ForgeDesign is the front end of the machine building process — concept a new machine, analyze whether to consolidate existing equipment, or build the business case for an upgrade. Proposals go out as PDFs. Wire swap plans go to ForgeSchematics. BOMs go to ForgeProcure.
Why it's different
"Consolidation analysis that produces a wire swap plan — not just a payback calculation."
ConsolidationSchematicHandoff classifies every wire on both existing machines as KEEP, EXTEND, REPLACE, NEW, or RETIRE. Exported as .forgeschematic — ForgeSchematics imports it and draws the panel. The analysis and the schematic handoff are one step.
"Import real machine data from .forgepkg — IO counts, wire lists, component BOMs — not estimates."
If the machines were built with Forge, import their .forgepkg files. ForgeDesign reads actual IO point counts, actual wire gauge and color, actual component catalog numbers. Consolidation analysis uses real data instead of station-type averages.
"Proposals generated as PDF via CoreGraphics — executive summary, ROI table, station layout, investment breakdown. No InDesign, no Word template."
ProposalGenerator uses CoreGraphics and CoreText directly. Customer name, engineer name, project number, revision, and date are embedded. Table formatting, section numbering, and page headers are automatic. The PDF is what goes to the customer.
Add your existing machines, run the analysis, get a proposal and wire swap plan — in one session.
Enter each machine: name, operations it performs, footprint, operators, annual maintenance cost, downtime hours, year installed, and condition. Import .forgepkg files for real IO counts and wire data.
ConsolidationAnalyzer generates three options: current state (baseline), full consolidation (all machines into one), and partial consolidation (compatible operations grouped). Each option calculates capital cost, annual savings, payback years, operator reduction, and floor space reclaimed.
Side-by-side ROI table compares all options. Payback chart shows cumulative savings vs. investment over 10 years. Incompatibility warnings flag operations that cannot be combined (different cycle times, conflicting safety requirements).
Select a consolidation option. ForgeDesign generates the .forgeschematic handoff: every wire from every existing machine classified as KEEP/REPLACE/RETIRE/NEW. Open in ForgeSchematics to draw the actual panel.
Enter customer name, engineer name, and project number. ProposalGenerator creates a PDF: executive summary, ROI analysis, proposed station layout, investment breakdown, and next steps.
Drag stations onto a canvas: manual assembly, robot weld, robot pick-place, vision inspection, press, test/gauge. Cycle time analysis and line balancing automatic.
Enter your existing machines. ForgeDesign calculates full and partial consolidation options with capital cost, savings, payback, operator reduction, and floor space savings.
Import machines built with Forge. Real IO counts, real wire lists, real component BOMs replace station-type estimates instantly.
Scaled floor plans showing current multi-machine layout vs. consolidated. Operator positions, panel locations, maintenance clearances.
Select a consolidation option. Every wire on every existing machine is classified and exported as .forgeschematic for ForgeSchematics.
Customer-ready proposal documents via CoreGraphics — executive summary, ROI table, station layout, investment breakdown. No template software required.
3
Consolidation options
Baseline, full consolidation, partial consolidation
2.6 yr
Typical payback
Based on $75K/yr operator cost, $15/sq ft space
.forgeschematic
Wire swap handoff
ForgeSchematics imports and draws the panel
8 sections
Auto-generated proposal
Cover to next steps, no template software
ForgeDesign is the starting point. Real machine data flows in from Forge packages. Outputs flow to ForgeSchematics, ForgeProcure, and the customer.
Forge .forgepkg
Existing machine packages with real IO and BOM data
ForgeOps
Live machine data for accurate maintenance cost inputs
ForgeSchematics
.forgeschematic file with classified wire list
ForgeProcure
BOM from new machine station configuration
Customer PDF
Proposal with ROI table, layout, and investment breakdown
New build or consolidation — start on the canvas, finish with a proposal PDF and a handoff to the Forge stack.