Can a single platform truly cut costs, boost throughput, and speed time-to-market without disrupting the plant floor?
We help U.S. manufacturers align technology roadmaps with clear business outcomes, combining configurable modules and tailored code to fit unique plants, lines, and sites.
Our discovery-led approach maps processes, constraints, and compliance, then defines architecture, integrations, and phased delivery that minimize downtime.
We blend domain expertise with engineering excellence so solutions scale, sustain production loads, and integrate securely with enterprise ecosystems.
Using cloud-native patterns, containerization, and DevOps, we increase deployment frequency, keep quality high, and lower maintenance overhead while protecting uptime.
Governance ties stakeholder priorities to the backlog, ensuring every release maps to KPIs shown on executive dashboards, and our embedded quality practices make each release dependable on the shop floor.
Key Takeaways
- We deliver enterprise-grade solutions that target measurable ROI for your plant and business.
- Configurable modules plus targeted custom code avoid overbuilding while handling edge cases.
- Discovery-led planning reduces disruption and clarifies compliance and integration needs.
- Cloud-native and DevOps approaches speed delivery and lower operational burden.
- Governance and embedded quality ensure every release advances clear KPIs.
Purpose-Built Custom Manufacturing Software for U.S. Manufacturers
Our team designs purpose-built systems that reflect U.S. compliance, local supply networks, and shop-floor realities, so your operations get practical, ready-to-run tools that match market demands and regulatory obligations.
We prioritize high-value use cases, tackling throughput bottlenecks, scrap reduction, labor utilization, and inventory accuracy first so each release boosts efficiency and delivers measurable business impact.
We integrate cleanly with legacy ERPs, bespoke schedulers, and line-side terminals to reduce risk and speed time to value. User experiences are tailored by role—from supervisors to warehouse teams—emphasizing clear interfaces and mobile access.
Collaboration is central: workshops and prototypes validate assumptions early, de-risk the project, and keep your team aligned as needs evolve. We adopt a tech-agnostic stance that avoids lock-in and supports scalability across plants.
- Flexible routing & shift changes to handle demand swings.
- Sector-aware logic for discrete, batch, and continuous environments.
- Built-in governance with access controls and audit trails to protect IP.
Manufacturing Software Development Services
We build end-to-end systems that connect planning, shop-floor control, product lifecycle, and quality assurance.
Our approach prioritizes clarity and interoperability so teams can trust the information they use to run production.
Enterprise Resource Planning (ERP) for production and planning
We extend ERP with production-specific capabilities for planning, finite capacity scheduling, and order orchestration, ensuring BOMs, routings, and work centers feed accurate plans and budgets.
Manufacturing Execution Systems (MES) for real-time shop floor control
Our MES captures real-time states across lines and stations, using machine connectivity and operator inputs to drive adjustments, enforce work instructions, and raise first-pass yield.
Product Lifecycle Management (PLM) from design to delivery
We implement PLM to unify product information across drafting, prototyping, validation, testing, and release, creating a single source of truth that speeds engineering change cycles.
Quality Management Systems (QMS) for compliant production
We configure QMS to monitor and document quality processes, including automated visual inspection and SPC, aligning to FDA, ISO, IATF, or HACCP requirements to protect product quality.
- Interoperability: ERP-MES-PLM-QMS cascades BOM and routing changes to the shop floor.
- Traceability: Link lots, serials, and process parameters from raw materials to finished goods for audits and recalls.
- Governance: Master data stewardship, validation rules, and phased project rollouts reduce risk and prove value.
| Capability | Primary Benefit | Typical Outcome |
|---|---|---|
| ERP Extensions | Accurate planning & cost control | Reduced stockouts, better budgets |
| MES | Real-time control & yield improvement | Higher throughput, fewer defects |
| PLM | Unified product information | Faster releases, fewer change errors |
| QMS | Regulatory alignment & inspection | Consistent quality, protected reputation |
We tailor configurations to your company’s requirements, balancing out-of-the-box best practices with targeted custom manufacturing software where niche steps demand it. Together, we plan phased rollouts that deliver measurable results and scale to broader sites.
Operations, Supply Chain, and Inventory Optimization
Real-time tracking and analytics turn warehouse activity from guesswork into predictable outcomes, so teams can prevent shortages, accelerate fulfillment, and lower carrying costs.
Inventory and Warehouse Management with RFID/barcode tracking
We implement dock-to-stock visibility, using RFID and barcode scanning to improve cycle counts, reduce inaccuracies, and cut inventory holding costs.
Our WMS automates label printing, guided picking and packing, wave planning, and dock scheduling so warehouse tasks align with production signals.
Supply Chain Management and end-to-end traceability
We deploy track-and-trace tools that link raw materials through production to finished product, enabling rapid recall management, supplier accountability, and audit-ready reports.
Multi-location inventory management ties into planning, smoothing imbalances with transfers, reorder policies, and safety stock tuned to lead-time variability.
Logistics Performance Management and route optimization
Dashboards and analytics surface route efficiency, cost-to-serve, and dwell times so planners can optimize carriers and schedules.
- RMA and shelf-life controls ensure FEFO/FIFO compliance and safe dispositioning of returns.
- Exception alerts flag potential stockouts, excess, or quality holds before they affect service levels.
Equipment Maintenance and Overall Equipment Effectiveness
Keeping critical assets running takes focused monitoring and workflows that turn sensor signals into timely action. We combine edge telemetry, coordinated work orders, and clear KPIs so maintenance aligns to production windows and business goals.
IoT Sensor Monitoring for predictive service
We connect assets to IoT gateways to capture temperature, vibration, current, and pressure, feeding models that flag anomalies before failures occur.
Itransition and Go Wombat examples show how live data prevents bottlenecks and short repairs that would otherwise delay runs.
CMMS workflows to reduce downtime and boost OEE
We integrate CMMS with MES and ERP so work orders respect production windows, spare parts are ready, and labor is scheduled without surprise outages.
- OEE dashboards decompose availability, performance, and quality losses to pinpoint micro-stops and slow cycles.
- Condition-based maintenance replaces calendar-only PMs, lowering unnecessary tasks while protecting key parts.
- Mobile maintenance apps give technicians procedures, history, and parts lists at the point of work for accurate captures.
- We secure telemetry pipelines and device identities to protect data confidentiality across plant and cloud systems.
Customer, Sales, and Revenue Enablement
Sales and service teams perform better when customer context, operational capacity, and pricing logic are unified in one platform.
We build CRM applications that analyze customer and market data, giving teams a 360-degree view of accounts, opportunities, and service history.
This unified view improves forecast accuracy, surfaces churn indicators, and enables targeted campaigns that increase lifetime value.
Configure-Price-Quote (CPQ) for complex products
We deliver CPQ engines with rules, pricing, and approvals that generate accurate quotes for configurable product lines and speed cycle times.
Automated proposals include branded templates, engineering drawing links, and T&Cs so quotes are complete and error-free.
- Integrate CRM and CPQ with ERP and MES to reflect capacity, lead times, and true costs in each quote.
- Track margin at the quote line with discount guardrails to protect profitability.
- Support channel partners with portals for quoting, order status, and documentation access.
- Provide role-based dashboards and analytics on funnel velocity, win/loss reasons, and price realization.
Why this matters: tying commercial processes to operations reduces fulfillment risk, speeds sales cycles, and helps teams convert opportunities into predictable revenue.
Data, Analytics, and AI for Smarter Manufacturing
We turn high-frequency sensor feeds and operational records into decision-grade information that reduces downtime, improves forecast accuracy, and ties analytics to action across the plant and supply chain.
Predictive maintenance from high-frequency sensor data
We build data pipelines to ingest fast telemetry from machines and lines, enabling models that predict failures before they interrupt production.
This approach protects critical equipment and lowers unplanned repair costs, using MLOps practices for versioning, monitoring, and safe retraining so models stay accurate as conditions change.
Demand forecasting and inventory right-sizing
Using statistical and machine learning methods we improve forecast accuracy and smooth production plans.
Right-sized inventory balances service and cost, and scenario simulations quantify trade-offs between lead time, capacity, and service levels.
Executive dashboards with Power BI and data visualization
We design Power BI dashboards that unify KPIs across operations, finance, and quality, with drill-throughs and certified datasets for trusted reporting.
- Deploy anomaly detection to surface out-of-control process parameters early, cutting scrap and rework.
- Optimize logistics with analytics on route efficiency, carrier performance, and dwell times.
- Implement data governance that defines ownership, lineage, and quality rules for audit-ready information.
- Connect alerts to ERP, MES, or maintenance workflows so insights trigger practical operational fixes.
For real-world examples of AI applied to production, see our case studies on AI in manufacturing examples, including fleet electrification and drilling-condition analytics used by The Virtual Forge and forecasting platforms built by Itransition.
How We Deliver: Custom Software Development Lifecycle
We organize each project around clear outcomes, aligning teams and timelines so technical work maps directly to business goals and acceptance criteria.
Discovery and requirements for your unique processes
We begin with focused discovery to document processes, policies, and constraints, capturing requirements that anchor scope and success metrics.
UX/UI design and rapid prototyping
Design sprint facilitation yields a high-fidelity prototype within five days, letting stakeholders validate flows before code is written.
Agile development, testing, and quality assurance
We deliver in iterative sprints, embedding unit, integration, and automated regression testing so defects are found early.
Cloud-ready deployment, DevOps, and ongoing support
Using DevOps patterns like CI/CD and infrastructure as code, The Virtual Forge integrates ops across the lifecycle for reliable releases.
- Performance testing: peak-load and device-condition validation prior to go-live.
- Data management: defined models, migration plans, and lineage visibility for clean cutovers.
- Post-launch: SLAs, monitoring, and service desk support for smooth adoption.
| Phase | Key Activity | Outcome |
|---|---|---|
| Discovery | Process mapping, requirements capture | Clear scope and acceptance criteria |
| Design | Design sprints, prototypes | Validated UX, reduced training |
| Delivery | Agile sprints, embedded QA | Working increments and low defects |
| Ops | CI/CD, cloud deployment, service desk | Reliable releases and fast support |
Business Outcomes You Can Measure
We translate technical work into measurable business gains, so teams can see faster prototyping, stronger quality, and real cost improvements in one view.
Accelerated time-to-market and faster prototyping
Faster prototypes, shorter approval cycles
We track prototype cycle time, engineering change lead time, and first article approvals to quantify speed gains. Integrated PLM and automated workflows shrink iterations and lower launch risk.
Improved product quality and regulatory compliance
Stronger traceability and fewer defects
We measure first-pass yield, defect density, and complaint rates, using automated inspection and controlled documentation for audit-ready compliance. Itransition’s work highlights these gains in regulated lines.
Operational efficiency, cost reduction, and throughput gains
Higher OEE and leaner inventory
We report setup time reductions, schedule adherence, and inventory turns so leaders see throughput and cost savings. Go Wombat examples show faster prototyping and ERP-driven operations modernization.
| Measured Area | Key Metric | Typical Improvement |
|---|---|---|
| Time-to-market | Prototype cycle time, ECN lead time | 30–50% faster approvals |
| Quality | First-pass yield, defect density | 20–40% fewer defects |
| Operations | OEE, setup time, inventory turns | 10–25% throughput gain, lower carrying costs |
- ROI validation: baseline vs. post-launch KPIs and governance reviews.
- Continuous improvement: data-driven backlogs feed future increments.
- Financial clarity: margin and cost-to-serve analytics inform pricing and sourcing.
Industry Expertise Across Manufacturing Verticals
Our industry teams bring sector-specific patterns that reduce launch risk and accelerate stable production. We combine compliance know-how, data-driven design, and practical execution so your lines meet audits and market cadence.
Automotive and complex assembly environments
We support complex assembly and high-traceability lines, implementing BOM explosion accuracy, line balancing, torque capture, and Poka‑Yoke to meet IATF and OEM expectations.
Testing and calibration stations are integrated into MES to record serial-level results for service, warranty, and audit trails.
Food and beverage compliance and traceability
We build recall-ready genealogy and COA tracking, with allergen controls, HACCP/FSMA alignment, and shelf-life rules that protect consumers and brands.
Consumer electronics and rapid innovation cycles
We enable faster NPI and tighter supplier collaboration through PLM workflows and rapid ECO handling, ensuring product quality keeps pace with short cycles. Our company templates adapt execution and planning for discrete, batch, or hybrid processes.
- Labeling, serialization, and packaging compliance at scale.
- Analytics that reveal yield drivers, substitution impacts, and supply risk.
- Multi-plant templates that speed rollouts while preserving local flexibility.
We turn sector best practices into pragmatic solutions that stabilize output and advance your business goals.
Seamless Integrations with Your Manufacturing Systems
A unified integration layer keeps planning, execution, and quality aligned so decisions are based on a single, trusted dataset.
We design integration architectures that align ERP, MES, PLM, and QMS so BOMs, routings, specs, and quality records stay synchronized across the product lifecycle.
ERP, MES, PLM, and QMS interoperability
Our approach standardizes master and transactional data models, aligning identifiers for products, assets, and materials to remove duplicate work and speed reconciliation.
Edge, shop-floor devices, and equipment connectivity
We normalize signals from PLCs, sensors, and test stations so upstream systems consume consistent, trustworthy data.
- Secure APIs, message queues, and event streams decouple systems for resilience and scalability.
- Supply chain links via EDI and APIs enable order, ASN, and shipment visibility.
- Inventory and maintenance sync ensures spare parts and work orders are coordinated to cut downtime.
- Cybersecurity controls—identity, encryption, and device trust—protect data across plant and enterprise networks.
| Integration Area | Primary Benefit | Delivery Practices |
|---|---|---|
| ERP ↔ MES ↔ PLM ↔ QMS | Synchronized product and quality records | Canonical models, API contracts, phased cutover |
| Edge & Equipment | Reliable telemetry and event normalization | Edge gateways, protocol adapters, test harnesses |
| Supply Chain & Inventory | Visible orders and parts, fewer stock surprises | EDI/API adapters, master-data stewardship |
| Monitoring & Security | Reduced outages, protected interfaces | Alerting, observability, device identity |
We manage each integration project with clear requirements, rollback plans, and continuous monitoring so cutovers are de-risked and business continuity is preserved.
Quality, Testing, and Security You Can Trust
Our approach combines automated validation, threat scanning, and performance proofing to protect uptime and data. We embed quality engineering across the lifecycle so every release aligns to acceptance criteria and real-world expectations.
We apply continuous testing, code review, and security controls to keep velocity high while lowering risk. The Virtual Forge enforces secure SDLC practices, dependency scanning, and secrets management so vulnerabilities are caught early.
- Automated tests: regression, API, and UI suites that prevent regressions and preserve delivery cadence.
- Performance validation: stress, soak, and load tests that prove responsiveness and graceful degradation under peak demand.
- Security hygiene: SAST/DAST, peer reviews, and least-privilege policies to protect IP and operational data.
We also operationalize data and AI governance with documented lineage, model monitoring, and explainability checks so models remain ethical and compliant.
Cloud architectures are designed for resilience and cost-effectiveness, using multi-zone patterns, autoscaling, backups, and clear recovery objectives. Release gates tie testing, security, and acceptance to production cutover, and we report KPIs that make quality and security improvements visible to the business.
Proof of Impact and Partnership Approach
We quantify outcomes with customer-facing dashboards and clear pre/post KPIs that link technical change to business results, so leaders see the effect on operations, quality, and cost.
Real-world case studies and measurable results
We demonstrate impact through focused examples and published metrics.
- Magnaflux: improved global financial reporting with Power BI, consolidating data and shortening monthly close cycles.
- Kelda Dynamics: delivered a precision control solution for drilling in depleted wells, reducing variance and improving run consistency.
- Each engagement defines baselines, tracks dashboard evidence, and reports measurable gains tied to the project.
Why partner with our experienced, innovative, and reliable team
We combine quality-first engineering, DevOps rigor, UX design, AI, cloud, and data expertise so projects move from prototype to hardened solution with minimal risk.
- Transparent governance and cadence for executive visibility and risk control.
- Co-ownership of outcomes, documentation, and knowledge transfer for long-term sustainability.
- SLAs, proactive maintenance, and continuous improvement to keep operations steady.
Conclusion
We focus on pragmatic roadmaps that mitigate risk, speed delivery, and keep operators and leaders aligned on outcomes.
Our approach ties discovery through DevOps and support to measurable KPIs, so each project advances plant performance and long-term value.
We integrate ERP, MES, PLM, and QMS with edge connectivity and secure cloud patterns to create end-to-end visibility and tighter control.
Data and AI power predictive maintenance, demand forecasting, and executive dashboards that make performance transparent and actionable for operations and management teams.
With deep sector experience across automotive, food and beverage, and consumer electronics, we transfer knowledge, co‑own outcomes, and tune solutions to fit your floor and enterprise needs.
Start with a short discovery to scope outcomes, define requirements, and map a pragmatic roadmap—so targeted initiatives deliver quick wins and scalable, secure growth.
FAQ
What types of custom solutions do we build for U.S. manufacturers?
We design purpose-built systems including enterprise resource planning for production planning, execution platforms for real-time shop-floor control, product lifecycle tools from design to delivery, and quality management solutions that support regulatory compliance and continuous improvement.
How do we improve inventory visibility and supply chain traceability?
We implement inventory and warehouse management with RFID and barcode tracking, integrate end-to-end supply chain systems for traceability, and deploy logistics performance tools to optimize routing and reduce lead times, so you can lower stock costs and increase fulfillment accuracy.
Can we help reduce equipment downtime and improve OEE?
Yes, we connect IoT sensors to monitor machine health, build predictive maintenance models, and configure computerized maintenance management workflows to schedule repairs proactively and boost overall equipment effectiveness while lowering unplanned outages.
What customer and sales enablement features do we offer?
We deliver CRM integrations that capture client insights and retention metrics, plus configure-price-quote solutions for complex products, enabling sales teams to create accurate, compliant quotes quickly and track revenue opportunities through the full lifecycle.
How do we use data and AI to inform operations?
We apply analytics and machine learning to sensor and transactional data for predictive maintenance, demand forecasting, and inventory right-sizing, and we build executive dashboards with Power BI or equivalent visualization tools to surface actionable KPIs.
What is our typical delivery approach for custom projects?
We begin with discovery and requirements gathering tailored to your processes, follow with UX/UI design and rapid prototyping, run iterative agile development with testing and quality assurance, and complete cloud-ready deployment with DevOps and ongoing support to ensure measurable results.
How do we ensure integrations with existing systems like ERP, MES, and PLM?
We design interoperable APIs and middleware, validate edge and shop-floor connectivity, and map data models to ensure seamless information flow between ERP, MES, PLM, and QMS platforms while preserving data integrity and minimizing disruption.
What testing, security, and governance practices do we apply?
We enforce rigorous QA, automated and performance testing, strong data governance and privacy controls, and AI model stewardship, and we architect scalable cloud infrastructures that meet enterprise security standards and regulatory requirements.
What measurable business outcomes can clients expect?
Typical outcomes include accelerated time-to-market, faster prototyping, improved product quality and compliance, reduced operating costs, higher throughput, and clearer operational metrics that drive continuous improvement and ROI.
Which industry verticals do we serve and what expertise do we bring?
We support automotive assembly, food and beverage with strict traceability needs, consumer electronics with rapid innovation cycles, and other sectors where equipment connectivity, quality, and supply chain resilience are critical.
How do we demonstrate proof of impact before full-scale rollout?
We validate concepts through pilot projects and case studies, deliver measurable KPIs during trials, and work closely with stakeholders to refine features so the full deployment delivers predictable benefits and reduced implementation risk.
What ongoing support and maintenance options are available?
We provide tiered support plans that include monitoring, preventative maintenance, patching, and feature enhancements, plus performance testing and managed cloud operations to keep systems secure, performant, and aligned with evolving business needs.