Stop Firefighting. Start Predicting.
ForgeOS watches every machine on your PCB shop floor, catches failures before they happen, and handles the scheduling and billing work that lives in spreadsheets.
The Cost of Unplanned Downtime
The numbers that make predictive maintenance obvious.
Predictive Maintenance Market
Growing at 21% CAGR through 2030
Per Hour Downtime Cost
One spindle failure can scrap an entire production run
Shops on Spreadsheets
Mid-size manufacturers still scheduling on paper
Preventable Downtime
Of total downtime in PCB shops is unplanned
One OS for Your Entire Shop Floor
Three integrated modules that replace your reactive CMMS, paper schedules, and manual billing.
Real-time floor visibility across every machine type
ForgeOS Monitor
Continuous machine health dashboard. Ingests sensor data from CNC routers, drill presses, and reflow ovens in real time. Surfaces anomaly scores and alerts operators before failures cause downtime.
- Real-time sensor ingestion
- Anomaly score per machine
- Instant failure alerts
Maintenance Scheduler
Reads machine health signals and generates, assigns, and tracks maintenance work orders automatically. No more email chains or whiteboard schedules.
- Condition-based PM triggers
- Auto-assign to technicians
- Work order tracking
ForgeOS Billing
Ties machine run hours and maintenance events directly to job records. Generates invoices automatically. Stop losing 5–10% of margin to unbilled machine time.
- Machine-hours → invoice
- Auto job reconciliation
- Monthly close in minutes
From Sensor to Invoice — Fully Automated
Three steps from installation to operational intelligence.
Install Sensors
Mount lightweight IoT sensors on your CNC routers, drill presses, and reflow ovens. ForgeOS starts ingesting vibration, temperature, and current data in minutes.
AI Detects Anomalies
Pre-trained models for PCB equipment catch failure signatures — spindle degradation, oven drift, abnormal current draw — before they cause a breakdown. No data science team required.
Auto-Generate Work Orders + Invoices
ForgeOS creates maintenance work orders, assigns them to your techs, and ties every machine-hour to the right job record for automatic invoicing.
PCB shop floors running ForgeOS see results in 30 days
Built for PCB Shops. Not Retrofitted.
Legacy CMMS tools were designed for reactive ticketing — not continuous prediction. Here's how ForgeOS stacks up.
| Feature | ForgeOS | Fiix (Rockwell) | UpKeep |
|---|---|---|---|
| Real-time sensor ingestion | |||
| Predictive anomaly detection | |||
| Auto-maintenance scheduling | Manual only | Manual only | |
| Automated billing from machine hours | |||
| PCB equipment pre-trained models | |||
| Mid-market pricing | $45–150/user/mo | ~$30/user/mo |
“One prevented machine failure pays for a year of ForgeOS.”
Simple Pricing by Machine Count
Start with your most critical machines. Expand as you see ROI.
Starter
Up to 5 machines
- ForgeOS Monitor (up to 5 machines)
- Anomaly alerts & email notifications
- 30-day machine health history
- Email support
Professional
Most PopularUp to 20 machines
- Everything in Starter
- ForgeOS Maintenance Scheduler
- Auto-generated work orders
- ForgeOS Billing module
- Priority support + onboarding
Enterprise
20+ machines
- Everything in Professional
- Dedicated sensor installation
- Custom anomaly model training
- SLA + uptime guarantee
- Dedicated success manager
All plans include a free 30-day sensor pilot on one machine.
Common Questions
Everything PCB shop operators ask before getting started.
Free 30-Day Pilot
See What's Actually Happening on Your Floor.
We'll install sensors on your most critical machine for 30 days and deliver a written failure-risk report — in dollar terms. No commitment, no sales pressure.
Or email us directly at forgeos@leapd.ai