Plant Overview

Turn machine telemetry, production data, quality signals and plant operations into actionable intelligence. Forge Guardian sits above your existing SCADA, PLC and IIoT infrastructure.

Illustrative demo data

Overall Equipment Effectiveness

86.7%

Availability 92.1 · Perf 94.3 · Quality 99.8-2.7 pts vs 7-day

Units Produced (shift)

5,142

Target 5,600 · 91.8% attainment

Downtime This Shift

74 min

38 min active · 792 units lost

Potential Savings Identified

$105,900

6 active AI recommendations

First Pass Yield

97.6%

Defect rate 2.4% · drift +0.6 pts

Machine Health

14 healthy

5 warning · 0 critical

Current Plant Power

412kW

3,186 kWh · $382 this shift

Predicted Failures

2 high-priority alerts open

Real-Time Plant Status

INFEED → MACHINING → ASSEMBLY → QA → PACKOUT · click a stage to inspect its assets

Open plant map

MACHINING assets

CNC-201

5-Axis CNC Machining Center

warning

Health

82%

Vibration

6.8 mm/s

Energy

18.4 kW

AI: Spindle bearing degradation likely — failure window 7–14 days

SM-201

Spindle Motor

warning

Health

84%

Vibration

6.1 mm/s

Energy

16.9 kW

AI: Elevated load signature correlated with CNC-201 spindle event

CP-201

Coolant Pump

normal

Health

90%

Vibration

2.9 mm/s

Energy

2.3 kW

AI: Performance drift — review in 30+ days

HY-201

Hydraulic Power Unit

normal

Health

93%

Vibration

2.1 mm/s

Energy

4.8 kW

AI: No degradation signature detected

COMP-01

Plant Air Compressor

warning

Health

87%

Vibration

2.1 mm/s

Energy

68.2 kW

AI: Efficiency degradation — compressed-air leakage suspected (14–21 days)

AI Detection

Detected 14 minutes ago · CNC-201

CRITICAL

Abnormal spindle vibration pattern

Classification: Mechanical degradation · Potential component: Spindle bearing (front pack)

Confidence

94.2%

Risk

HIGH

Failure Window

7–14 days

Exposure

$114,400

AI Interpretation

What changed against the 90-day operating baseline

Vibration4.9 mm/s6.8 mm/s+38.8%
Spindle Temperature63 °C72 °C+9 °C
Energy Consumption17.2 kW18.4 kW+7.2%
Average Cycle Time40.9 s42.8 s+4.6%

Signal → Decision

How Forge Guardian turns one telemetry deviation into an approved action

SIGNAL

Spindle vibration rises from 4.9 → 6.8 mm/s

AI DETECTS

Pattern deviation vs. 90-day baseline

AI INTERPRETS

Possible spindle bearing degradation

AI PRIORITIZES

HIGH PRIORITY — machining is line-critical

AI QUANTIFIES

$114,400 potential exposure

AI RECOMMENDS

Inspect bearing during planned maintenance

OPERATOR DECIDES

Approve, edit or dismiss the recommendation

OEE Trend

Seven-day plant trend

Prioritized Events

247 raw signals → 8 operational events

All alerts

Predicted Failures

Ranked by exposure and confidence

Predictive maintenance

CNC-201HIGH

Spindle bearing degradation

Vibration +38.8%, temperature +9 °C, current +7%, cycle time +4.6%

Window 7–14 days · 94.2% confidence$114,400

R-301MEDIUM

Robot gearbox vibration anomaly

Axis-3 vibration +20% vs. peer cells, gearbox temp +4 °C

Window 21–30 days · 82.5% confidence$41,200

COMP-01MEDIUM

Compressor efficiency degradation

Duty cycle 78% → 92% at flat production volume

Window 14–21 days · 88.6% confidence$31,000

CP-201LOW

Coolant pump performance drift

Flow down 4% at constant pressure setpoint

Window 30+ days · 71.3% confidence$9,800

The Difference

Traditional systems

Show you what the machine is doing.

SCADA screens, tag values, threshold alarms — accurate, but they leave interpretation, prioritization and costing to people.

Manufacturing Intelligence

Explains what is happening, why it matters, what is likely to happen next and what action to take.

See the sensor-to-decision architecture