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Track 09 · Manufacturing OS · Pilot

Forge.

AI-native Manufacturing OS. Replaces fragmented ERP / MES / WMS silos with one platform spanning Plan → Buy/Source → Assemble → Move. Live at NeoLync Tirupati · manufacturing Jio Air Fiber Wi-Fi devices. 100% on-premise · 50+ operators on platform.

Pilot · NeoLync Tirupati · Jio Air Fiber Wi-Fi Building · go-live validation · 15 categories Roadmap · plant-wide rollout · Industry 5.0 agentic stack

Pilot · live at NeoLync Tirupati · today's state

Production volume

~1,000

units · current run-rate

Peak throughput

3,000

TPS · high-volume runs

On platform

50+

operators · 25 line managers

Deployment

100%

on-premise · low-latency

Target outcomes

Plan cycle time

−90%

days → minutes

Throughput

+5–10%

line balancing + perpetual plan

Stockouts

−50%

predictive replenishment

Audit cycle time

−80%

in-line traceability + FPY

01 · The shift · Industry 4.0 → 5.0

From fragmented ERP / MES / WMS to one OS.

Today's EMS challenges

· Fragmented systems · ERP, MES, WMS, HRMS, spreadsheets each siloed
· Disconnected traceability · SN, IMEI, MAC IDs tracked inconsistently across stages
· Manual quality checks · SPI, AOI, X-Ray done reactively · no closed-loop automation
· Inefficient procurement · vendor onboarding, PO approvals, GRN reconciliation manual
· No real-time visibility · WIP and FG statuses updated by hand · no SLA alerts
· Costly downtime & rework · failures found late · low FPY

With Forge

· Unified Manufacturing OS · one AI-native digital backbone linking BOM, work orders, SN traceability, HRMS, QMS
· End-to-end genealogy · unique SN/IMEI binding from PCB → Assembly → QA → Carton → Shipment
· AI-powered quality · in-line defect detection · FPY monitoring · automated loopbacks
· Streamlined Procure-to-Pay · automated POs, vendor scorecards, 3-way matching, predictive replenishment
· Live dashboards & control tower · real-time WIP, OEE, SLA alerts
· Predictive maintenance · 30–50% downtime reduction · +2pp FPY

02 · The four AI-native stages

Plan · Buy/Source · Assemble · Move.

Forge organises the factory across four stages on a single fabric. Every stage on the same data spine · every action traceable from raw material to dispatched carton. Outcome metrics per the Fynd MOS deck.

01 · Plan

Pilot

Schedule, allocate, prepare.

NPI planning · BOM & version control · routing & engineering · IIoT integration · inventory, label, workforce, work order planning · compliance.

Outcome · forecast accuracy · lifecycle control · agility

02 · Buy/Source

Pilot

Procure, inspect, kit.

Vendor & customer traceability · Procure-to-Pay · material traceability · WMS · kitting · IQC · compliance management.

Outcome · supplier reliability · procurement efficiency

03 · Assemble

Pilot

SMT → BLT → FATP.

Replenishment & requisition · kitting tracking · station-level inventory · MES + QA · repair & scrap · failure record · workforce tracking.

Outcome · traceability · process reliability · compliance

04 · Move

Pilot

Pack, palletise, ship.

Scan → Pack · WIP & FG tracking · warehousing internal & shipping · ASN + e-invoice generation · customer approval & dispatch.

Outcome · fulfilment · SLA adherence · cost savings

03 · Architecture · key system modules

Eight modules · one fabric.

A unified data backbone connects every module through a central API and AI orchestration layer. No silos, no manual reconciliation between systems.

Plan

Procure-to-Pay (P2P)

Vendor management · PO · GRN · approvals.

Warehouse

Warehousing

FIFO · Handling Unit (HU) tracking · expiry alerts · cold storage monitoring.

Floor

MES + Production

SMT · SPI · AOI · Reflow · QA — fully integrated with route logic.

Engineering

BOM & Version Control

Multi-rev BOM · component substitution · ECO traceability · approvals.

Workforce

People & Labour

Workforce productivity · access control · role-based dashboards.

Customer

Client Management

Order / SLA visibility.

Connect

Integrations & Webhooks

Technical integration of tools & equipment · HRMS · GreyHR · SAP · Infor.

Brain

AI Orchestration

Central intelligence layer connecting all modules.

04 · Pilot · NeoLync Tirupati · Phase 1

Live at NeoLync Tirupati · Jio Air Fiber Wi-Fi.

Forge is deployed at NeoLync's Tirupati facility supporting Jio Air Fiber Wi-Fi device manufacturing. Current production run-rate ~1,000 units. Platform handles peaks of 3,000 TPS during high-volume runs. 50+ operators and 25 line managers are on Forge today. Deployment is 100% on-premise — high reliability, complete data control, low-latency operations. End-to-end traceability across the entire production process. Pilot rollout in progress; plan is to extend Forge across all production sites and product lines within the plant.

Go-live validation runs against a 15-category checklist (v2.0 · 07-Apr-2026). Phase 1 covers planning & traceability, quality & repair, scan-pack, ASN, and predictive maintenance. Each item carries a Fynd development status, a NeoLync site readiness status, a DRI / reviewer pair, and a target date.

What plant managers and operators see.

Six surfaces from the Forge MES live at NeoLync Tirupati. Real product, real serial numbers, real BOMs · captured 30-Apr-2026.

Analytics Dashboard

Live

Plant Administrator landing · Plant Health Score · OEE · FPY · Active Work Orders · 222/222 stations running · 136 total users.

Work Order timeline

Live

Work order #1023044 · LUX MICRON DDR JIDU6601 · 10 PCS · 30 stages · 44 steps · 270 logs · real serial numbers. Client: JIO. Pack-QC inspection step detail expanded.

Bound identifiers + BOM

Live

Per-unit identifier binding · REGNO · MAC · DDR / ACS / BTRY / FCBA / MODEL_NAME · partition IDs. BOM Progress shows component-by-component pull (PALLET CARD TRAY, PALLET PE BAG, PALLET CRAFT ANGLE, etc.).

Sampling / QC

Live

43 samples · 24 passed · 55.8% pass rate · TAT 4h 46m. Breakdown across IQC types (ORT, Incoming QC, Outgoing QC, Pre-Delivery, Aging, In-Process QC). 7-day inspections trend.

Inventory Dashboard

Live

17,772 components · 129,410 lots · 1.46B units on hand. Stock by storage location · stock by category (Thermal Paste 32% · Chassis Housing 19% · Main Control Board PCB 16%). Top suppliers by value.

Operator UI · shop-floor

Live

Assy-Visual Inspection station · reference images · scan/enter Task ID or Serial Number · 11-step inspection instructions in plain English. Stop-line on Fail Task.

#	Category	Scope
01	Product Master & SKU configuration	FG / SFG SKUs · attributes · images · customer mapping
02	Material Master & Inventory	Raw material masters · UoM · storage classification
03	Bill of Materials (BOM)	Multi-rev BOM · component substitution · ECO traceability
04	Routing, Stations & Work Instructions	Site → Line → Station hierarchy · routing & operations · digital work instructions
05	Production Line Infrastructure & Machine Readiness	Machine & equipment configuration · network & internet connectivity
06	Forge Edge Client & Automation Tools	Edge install · machine log reading · data sync reliability · automation tools
07	Serialisation, Identifiers & Unit-Level Traceability	SN · RSN · IMEI · MAC ID · PSN binding rules
08	Assembly, Accessories & Packing Configuration	Assembly readiness · packing configuration in Forge
09	Shift Configuration & Production Scheduling	Shift planning · work order release · skill-based allocation
10	Testing, Quality & Inspection	Pre-Assembly / PCBA testing · Post-Assembly / FATP testing · QMS
11	Order Management, Invoicing & Documentation	Customer order book · invoicing · documentation
12	Shipping, ASN & Dispatch	Advance Shipping Notice · e-invoice · dispatch flow
13	Forge Dashboards, Analytics & KPI Reporting	Live OEE · FPY · downtime · throughput · SLA dashboards
14	User Access, RBAC & Operator Training	RBAC · role-based UI · operator training
15	Go-Live Validation, Dry Run & Hypercare	Dry run · go-live cutover · hypercare window

Four agentic loops · measured.

Pilot

01 · Planning & Scheduling

Target KPIs

Mechanism

Perpetual plan · finite-capacity · auto-replan on disruptions · human-in-loop approvals.

Plan cycle time

−90% · days → minutes

On-time completion

+3–5pp

Throughput

+5–10%

Pilot

02 · Inventory & Supply Continuity

Target KPIs

Mechanism

Real-time stock · predictive replenishment · alternate sourcing · supplier collaboration · ASN tracking.

Stockouts

−50%

Inventory turns

1–2× higher

Expedites

−30 to −50%

Pilot

03 · Quality & Traceability

Target KPIs

Mechanism

In-line digital checks · AI vision defect detection · FPY monitoring · full genealogy from IMEI to component lot.

First Pass Yield

+2pp

Audit cycle time

−80%

Warranty / returns

Reduced (target)

Building

04 · Predictive Maintenance

Target KPIs

Mechanism

Condition monitoring · anomaly detection · RUL predictions · auto work orders · spares tie-in.

Unplanned downtime

−30 to −50%

MTBF

Higher (target)

Maintenance cost / throughput

Lower (target)