Industries · Production technology
Builders of production machines and plants for other industries, such as food processing, as well as manufacturers and suppliers lose time in places that rarely show up in a metric: shift handovers, outdated work instructions, complaints that keep coming back and knowledge that retires with one person.
The problem
On the shop floor, experience decides. Who knows why the line runs differently after the weekend, who knows the cause of the fault that returns every few months? That knowledge rarely lives in a system. It sits in shift logs, emails and the heads of a few experienced people.
AI can take a lot of work off their hands here: recording handovers, keeping instructions current, grouping complaints, structuring 8D reports. It does not replace experience, it makes it available to everyone.
Costed applications
From the use case library, calculated for a company with 100 employees and with the assumptions disclosed.
| Application | Area | Time per week | Savings per year | Set-up | Payback |
|---|---|---|---|---|---|
| Inspection instructions at the workstation | Quality and complaints | 6.0 h | €17,550 | €3,500 | 2.9 months |
| Audit preparation and QM reports | Quality and complaints | 3.2 h | €12,240 | €4,000 | 4.5 months |
| Structure 8D reports | Quality and complaints | 3.2 h | €12,240 | €4,000 | 4.8 months |
| Record shift handovers | Production and maintenance | 4.8 h | €14,040 | €4,000 | 4.9 months |
| Cluster customer complaints | Quality and complaints | 2.1 h | €8,032 | €3,500 | 8.4 months |
| Capture lessons learned | Production and maintenance | 2.0 h | €7,650 | €4,000 | 8.7 months |
| Keep work instructions up to date | Production and maintenance | 2.8 h | €8,190 | €3,500 | 10.4 months |
| Analyse downtime | Production and maintenance | 1.8 h | €6,885 | €35,000 | via downtime |
Time per week is the working time saved across the whole company. Payback is the set-up cost divided by the monthly surplus after running costs. “Analyse downtime” pays off through avoided downtime hours, not analysis time.
How we help
If you build machines and plants, you have to prove compliance with the Machinery Regulation, harmonised A, B and C standards and customer requirements for every machine. We build this into the development process instead of catching up at the end.
From the customer requirement through mechanics, electrics and software to acceptance: one continuous development process that keeps variants and special machines manageable.
FORGE Insights connects quality, complaint and operations data and shows patterns before they turn into a crisis.
Document Intelligence makes work instructions, shift logs and troubleshooting knowledge searchable.
ComplAInow keeps the evidence for your standards, such as ISO 9001 and ISO 13849, up to date at all times.
Every FORGE tool can run entirely within your own infrastructure.
Insights
AI and automation
Shift handover logs, work instructions, downtime analysis and lessons learned: four AI applications for machinery makers, with setup costs and payback.
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8D reports, complaint clustering, audit preparation and inspection instructions with AI: four applications for machinery makers, costed.
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