ForgeMachineForgeMachine is the authoritative machine lifecycle registry. Serial numbers, subsystem maps, PLC I/O catalogs, revision history, fault history, PM records, and job history — all in one place. ForgeOps, ForgeMaint, ForgeSchematics, and ForgeProcure read from it. You maintain it once.
Why ForgeMachine is the foundation
"Every Forge product reads machine state from ForgeMachine — one authoritative registry, not 6 separate data models."
ForgeOps reads cycle data and fault history. ForgeMaint reads PM schedules and subsystem maps. ForgeSchematics reads I/O catalog. ForgeCAD reads revision history. ForgeProcure reads tooling consumption. One record per machine, one source of truth. No synchronization problem because there is nothing to synchronize.
"An alarm resolves to a named subsystem in under 2 seconds — not a machine number and a guess."
ForgeMachine maps every PLC I/O tag to a specific physical subsystem. When a fault fires on tag DI_ZONE4_ESTOP, ForgeMachine knows that tag belongs to Conveyor Zone 4 Drive — manufacturer Bosch Rexroth, model MKE096B, serial SN-2291-A. ForgeOps dispatches a targeted repair order, not a general inspection.
"OEE is computed from cycle data, not from operator estimates or spreadsheets."
ForgeMachine reads PLC cycle counters directly. Availability = planned run time minus unplanned stops (from fault register). Performance = actual cycle time vs. ideal cycle time (from job spec). Quality = good parts vs. total (from vision or PLC). All three factors are derived from the same data source, updated per cycle.
Register a machine once. Everything else — faults, PM events, job history, tooling wear — is captured automatically.
Add a machine: manufacturer, model, serial number, commission date, plant location. Attach subsystem map — drive, conveyor, spindle, pneumatics. Assign PLC I/O tags from the catalog.
ForgeMachine connects to the PLC via one of 30+ manufacturer adapters. Tag values flow in continuously. Subsystem state updates in real time. No manual data entry after initial setup.
Cycle counters, fault registers, and energy meters are read per cycle. OEE is calculated live. Anomaly detection flags deviations from established operating envelopes.
Every fault, PM event, and engineering change is logged with a timestamp. Job history accumulates: parts produced, cycle time distribution, tooling wear. Revision history captures every hardware change.
ForgeOps, ForgeMaint, ForgeSchematics, ForgeCAD, and ForgeProcure read from ForgeMachine via the ForgeHub event bus. Changes to machine state propagate to every dependent product automatically.
Every machine decomposed into named subsystems — drive, spindle, pneumatics, PLC, vision. Each subsystem carries manufacturer, model, serial, and field data.
Every tag mapped to a named subsystem. When a fault fires on a tag, ForgeMachine knows which physical component it belongs to — manufacturer, model, serial included.
Availability, Performance, Quality — computed from PLC cycle counters and fault registers, updated per cycle. Not daily estimates.
Every hardware change, PM event, and engineering change is logged with a timestamp, operator, and linked source record. The full life of each machine is auditable.
Every job run on every machine: part number, quantity, cycle time distribution, reject count, tooling wear. Feeds ForgeProcure for automatic tooling reorders.
Machinists see their next job, required tooling, NC program status, and any active machine alerts — on an iPad at the machine. No paper travelers.
Jobs are scheduled against real constraints: machine PM windows, active faults, tooling availability, material stock. Not a Gantt chart disconnected from reality.
30+
Manufacturer device connections
Bosch, Fanuc, Siemens, Allen-Bradley, Mitsubishi, more
Per cycle
OEE update rate
Not daily estimates — live cycle data
6
Forge products served
One registry, no synchronization problem
< 2 sec
Fault-to-subsystem resolution
Tag → named physical component
ForgeMachine eliminates the data synchronization problem. Register a machine once — subsystems, I/O tags, PM schedule, job specs. ForgeOps, ForgeMaint, ForgeSchematics, ForgeCAD, and ForgeProcure all read from the same record. Nothing goes out of sync because there is only one record.