The reliable spine
The non-AI spine is the source-linked workflow: clean records, rules, calculations, integrations, exception queues, approvals and reporting for Production and job-work operations.
Metals, Foundries & Steel
Production and job-work operations
What is on the floor lives in one supervisor's head and a paper heat-card, charge sheet or job-card; nobody can say where a heat or an order has reached without walking the shop. Material issued against a heat or a job is not reconciled to good output, so scrap, yield loss and pilferage hide. The biggest in-plant leak is different by process: foundry (rejection by pattern, grade, heat, shift; melt yield), forging (material yield, die-life, heat-treat), re-rolling (heat-to-rolled yield, burning and reheat loss), fabrication (plate-nesting yield, fit-up and weld rework). Costing per heat or per job is an after-the-fact guess.
Who has it
Across all segments, and sharpest for foundries (scrap by pattern, grade and heat, and melt yield), forging and heat-treatment units (material yield and heat-treatment), re-rolling mills (heat-to-rolled yield and burning loss) and fabrication shops (project and work-in-progress tracking and plate-nesting).
What we build
A heat-card, charge-sheet and job-card workflow, material-issued-vs-good-output reconciliation by heat and grade, a yield record by furnace/grade/shift, and floor capture of stage and cost. The scrap layer clusters rejection by the variable that actually drives it for that process (pattern, grade, heat, shift for a foundry; section and surface for re-rolling; weld and dimension for fabrication).
What is automated, where AI helps, who signs off
Automation for the routine. A person on every decision that matters.
Where AI helps
AI is limited to bounded reading, extraction, matching, clustering or drafting from the firm's own data for Production and job-work operations; it never owns the number, the approval, the promise or the decision.
Who signs off
A named person signs off anything touching money, stock, a customer promise, a regulated filing, a payment, a price, a credit decision or a people decision.
What changes day to day
The owner sees what is in process and where without walking the floor; material reconciles to good output so scrap, yield loss and pilferage surface; the worst scrap patterns surface quickly. Illustrative: a casting house digitised heat-card and rejection capture, clustered scrap by pattern, grade and heat, and corrective action cut scrap on the worst patterns by about a quarter in the first few months. Illustrative; final numbers come from your own data.
Illustrative outcome
The owner sees what is in process and where without walking the floor; material reconciles to good output so scrap, yield loss and pilferage surface; the worst scrap patterns surface quickly. Illustrative: a casting house digitised heat-card and rejection capture, clustered scrap by pattern, grade and heat, and corrective action cut scrap on the worst patterns by about a quarter in the first few months. Illustrative; final numbers come from your own data.
Illustrative; final numbers come from your own data.
Path to the build
How this one gets built.
Book a free 60-minute call, then a free Blueprint on the firm's own records. Deep-dive and build, followed by run and govern so the workflow keeps paying back.
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What tends to pair with this one.
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