Built for the heat, the heft, and the heat numbers.
From sand-cast iron and aluminium foundries to laser-cut sheet metal and heavy structural fabrication — FactorialOS gives you yield analysis, weld traceability, melt-to-part genealogy, and the customer-grade quality records your buyers demand.
Where fabrication and foundry shops bleed money
Yield losses, rework, weld rejections, mould failures, NDT re-shoots. Most shops only see the damage at month-end — long after the cause is forgotten.
Foundry yield is invisible
Sand prep, melt, pour, fettling, heat treatment — losses happen at every stage. Without per-pattern, per-alloy, per-shift numbers, fixing scrap is guesswork.
Heat numbers and melt records
Customers want melt-to-part traceability. Charge composition, spectro reading, pour temperature, mould box, heat-treat batch — tied to every casting that ships.
Welding traceability is brutal
WPS-PQR, welder qualification, joint number, electrode batch, parameters — per joint, per part. Add NDT and the paperwork mountain doubles.
Moulds & patterns get lost
Where is the pattern for that part the customer wants again? Last run when? How many shots left before refurb? Most shops still track this on a board, or in someone’s head.
NDT re-shoots eat margin
RT, UT, MPI, dye-penetrant — a missed report costs you a re-shoot, a missed defect costs you a customer. Either way the margin is gone.
Customer-specific quality plans
Auto OEMs want PPAP. Energy customers want type-test data. Aerospace wants AS9102. Same shop, same machines — very different paperwork demands.
How FactorialOS handles it
Built for the way fabrication and foundry shops actually run — melt to dispatch, plate to assembly, with the records every downstream customer asks for.
Live yield by pattern, alloy & shift
See exactly where the yield is leaking — this pattern, this alloy, this shift, this furnace. Stop chasing month-end scrap reports.
Melt-to-part traceability
Charge composition, spectro reading, pour temperature, mould box, heat-treat batch — tied to every casting that ships, recoverable in seconds.
Welding records without paperwork hell
WPS-PQR, welder qualification, joint number, electrode batch, and parameters captured at the welding station. Auto-compiled into the customer’s required format.
Mould & pattern lifecycle
Where it is, last run date, shots done, shots-to-refurb, customer associations — for every pattern in your inventory. No more “ask the foundry foreman”.
NDT capture at the inspection point
RT, UT, MPI, dye-penetrant results recorded at the test station, tied to the part, ready for the customer’s quality dossier.
Per-customer quality plan execution
Same shop, different customers, different paperwork — PPAP for auto, type-test for energy, AS9102 for aerospace. FactorialOS routes the right plan to the right batch.
Where it fits in your plant
From iron and aluminium foundries to laser-cut sheet metal shops and heavy structural fabrication.
Iron, steel & non-ferrous foundries
Sand casting, investment casting, gravity die, pressure die. Charge to part traceability with live yield by pattern, alloy, and shift — for ferrous and non-ferrous shops alike.
- Charge composition and spectro records
- Mould box and pattern lifecycle
- Yield analysis by pattern, alloy, shift
Sheet metal fabrication
Laser, plasma, CNC bending, punching, welding, powder coating. Track every part from nesting to dispatch with material lot and operation-by-operation records.
- Material lot lineage from coil to part
- Nesting yield and remnant tracking
- Welding and surface treatment records
Heavy structural fabrication
Pressure vessels, structural assemblies, tanks, frames. WPS-PQR-grade welding traceability with NDT records and customer-specific quality dossiers.
- Joint-level welding records with parameters
- NDT (RT, UT, MPI) result capture
- Customer dossier auto-compilation
Forging shops
Open die, closed die, hot and cold forging. Heat number, billet lot, press parameters, heat treatment, and inspection records tied to every forging.
- Billet-to-forging lot traceability
- Press cycle and heat-treat batch records
- Die life and refurb tracking
What changes after FactorialOS
The shifts foundries and fabrication shops see in the first months on the floor — in numbers their owners care about.
Yield climbs, scrap drops
Per-pattern, per-alloy, per-shift visibility means losses get attacked at the source — not chased weeks later from a scrap report.
Welding rejection rates fall
Recording parameters, electrode batch, and welder per joint surfaces the patterns that drive defects — usually fixable quickly.
Customer audits stop being a fire drill
Auto, energy, oil & gas, aerospace customers all want different paperwork. With records auto-compiled, audits go from panic to walkthrough.
Pattern & mould chaos ends
Foreman walks to a board to find a pattern? Replace that with a search. Last run, location, refurb status, customer mapping — one click.
More throughput, same furnaces
Better visibility of melt utilisation, pour timing, and mould-prep delays adds up to more castings poured per shift.
Win bigger, more demanding customers
When the records are ready and the trace is clean, you can bid on auto, defense, and energy work that needs more discipline than spreadsheets can deliver.
Run your foundry or fabrication shop with the records your customers want
Bring us a part, a heat number, or a weld map. We’ll show you what FactorialOS looks like running it — live.
Built for ferrous and non-ferrous foundries, sheet metal, structural fabrication, and forging shops.