Twenty operations leaders.
One argument.
Every quote below comes from a VP or plant director who ran the numbers after a Forge engagement. We let their results make the case.
We recovered 14,200 machine hours in the first year. Forge didn't just fix our PLC stack — they rebuilt the logic our operators had been carrying in their heads for twenty years.
Marcus Webb
VP Operations · Dearborn Steel Works
Recovered
14,200 hrs
Year 1
Predictive Maintenance
When machines fail on the floor, not in the forecast — the cost isn't just the repair. It's every downstream hour that bled out waiting for parts that should have been on the shelf.
01
Our OEE was sitting at 61%. Six months after Forge integrated our vibration sensors with the MES, we're at 79% OEE and our maintenance team stopped reacting to fires they started preventing them.
Patricia Nwosu
Dir. Reliability Engineering · Meridian Precision
Result
+18pt
OEE improvement
61% → 79% in 6 months
Meridian Precision Components
Tier-1 auto parts · Grand Rapids, MI
Watch: 4-min walkthrough
Stamping press sensor retrofit
Unplanned downtime
−67%
Year-over-year reduction
Harmon Fluid Controls
Cincinnati, OH
"The tribal knowledge capture alone was worth the engagement. Two of our best maintenance techs retired in March — we didn't lose a single procedure."
Dale Kowalski
Plant Manager · Harmon Fluid
$2.1M
Avoided repair costs
Avg. across 6 engagements
4.2×
ROI on sensor integration
First 18 months
91%
Alert accuracy rate
ML model post-tuning
11 days
Mean time to first signal
From sensor install
Is your maintenance team reacting or predicting? A plant assessment surfaces the gap in one session.
Schedule a Plant Assessment →Production Scheduling
Siloed MES platforms and spreadsheet-driven scheduling don't fail loudly — they bleed throughput quietly, shift after shift, until the numbers stop making sense.
02
"We were running three separate scheduling systems that didn't talk to each other. Forge spent four weeks mapping the data flows before writing a single line of integration code. That diligence is why the rollout had zero production disruptions. We gained 3.4 additional production days per month without adding a shift."
Raymond Okafor
VP Manufacturing Operations · Cascade Industrial Group
Schedule adherence
94%
Up from 71% pre-engagement
Pinnacle Forming Co.
Metal stamping · Akron, OH
3-min overview
MES integration at Cascade Industrial
"The scheduler Forge built knows our machine constraints better than our planners did. Setup time reduction alone paid for the project in seven months."
Sandra Reyes
Ops Director · Pinnacle Forming
−23%
WIP inventory reduction
Cascade Industrial
7 mo
Time to project payback
Pinnacle Forming
+12%
Throughput increase
Atlas Machining
"I'd been trying to get our ERP and MES to share a production queue for three years. Forge mapped the data schema mismatch in the first week of their assessment. It was embarrassingly fixable — we just didn't have the right eyes on it."
Thomas Brannigan
VP Operations · Atlas Machining Solutions
A scheduling audit takes one day. The data gaps it surfaces typically represent weeks of recoverable throughput.
Schedule a Plant Assessment →Quality Traceability
A quality escape that reaches the customer costs 10× what it costs to catch at the press. Traceability isn't a compliance checkbox — it's the difference between a contained recall and a line shutdown.
03
Scrap rate
−41%
Post-traceability integration
Vantage Precision Castings
Investment casting · Dayton, OH
"We had a Tier-1 customer threatening to pull their contract over traceability compliance gaps. Forge came in, mapped every data hand-off from raw material to final inspection, and built us a system that generates AS9100-compliant records automatically. We kept the contract and won two more because we could demonstrate the capability."
Angela Marchetti
Quality Systems Director · Vantage Precision Castings
100%
Part genealogy capture
Lot to serial level
Vantage Precision
< 2hr
Recall containment time
Down from 3.5 days
Meridian Precision
$890K
Avoided warranty costs
First 12 months
Harmon Fluid
3 new
Contracts won on capability
Traceability as differentiator
Vantage Precision
"Our first customer audit post-integration was the smoothest in company history. The auditor said she'd never seen traceability data presented that cleanly at a shop our size."
Claire Hoffmann
VP Quality · Cascade Industrial
6-min walkthrough
Traceability system at Vantage Precision
Customer escapes
Zero
18 consecutive months post-deployment
Vantage Precision Castings
One quality escape at a Tier-1 customer can cost more than a full Forge engagement. The math isn't close.
Schedule a Plant Assessment →0 hrs
Machine hours recovered
Across all engagements
0%
Average ROI
First 18 months
0
Completed engagements
Mid-market manufacturers
0 wks
Avg. deployment time
Assessment to go-live
The question isn't whether Forge delivers.
It's whether your plant can wait another quarter.
"The ROI conversation with our CFO lasted about four minutes. The numbers were that clear."
Kevin Tran
VP Operations · Irongate Stamping
"We'd been told our PLC architecture was 'too legacy to integrate.' Forge proved that wrong in week two."
Deborah Szymanski
Plant Director · Northgate Fabrication
0
Failed deployments
23 for 23
91%
Clients expand scope
Within 12 months
4.9★
Client satisfaction
Post-engagement survey
"I've brought in three consulting firms over my career. Forge is the first one that walked the floor before they opened a laptop. They earned credibility before they spent a minute in a conference room. That's the difference."
Gerald Fontenot
Chief Operations Officer · Whitmore Manufacturing Group
Schedule a Plant Assessment.
A 60-minute session with a Forge systems engineer. We review your current architecture, identify the three highest-ROI integration opportunities, and give you a written scope — no commitment required.
Week 1
Floor walk + systems audit
Week 2
Gap analysis + ROI model
Week 3
Written scope delivered