Capture the method. Run it on the floor.
Digital work instructions for the plant launching its next product. Built by the team behind seven connected-worker deployments at BSH, Bühler, BMW North America, DHL Supply Chain, and Unipres. Start with a six-week Launch Pilot at $2,500 on one line. Then $1,000 per month, unlimited users, no minimums.
Connected-worker deployments led by our team:
Start with a pilot.
One line, six weeks, a price you can sign off on without a budget cycle.
Prove it on one line
Six weeks on a single production line, up to ten work instructions authored alongside your team, two RealWear HMT-1 headsets included. One invoice at $2,500, which credits in full toward your first annual if you continue. Most plants start here.
Start a Launch Pilot →You already know you need integration
Quick Start covers integration with your MES, ERP, CMMS, PLC stack, and computer-vision systems if you have them. Dedicated success manager. Deployment timeline matched to your launch schedule. Priced by scope.
Book a Quick Start call →Seven plants. One line our competitors cannot write.
Seven connected-worker deployments across automotive, appliance, industrial, and logistics. BSH. Bühler. BMW North America. DHL Supply Chain. Unipres.
We implemented, customized, integrated, trained, and supported those rollouts. For two of them we shipped the operator experience under the customer's own brand. We learned what works at that scale, what breaks, and what a plant actually needs on the floor. ForgeOS is what we built when we wanted to do it our way.
AI-assisted work instruction capture on a Bosch cooktop assembly line.
The video shows ForgeOS Method's WI capture workflow running on a Bosch Siemens Hausgeräte cooktop assembly line. AI-assisted instruction authoring from live observation of the operator at work. The same capture interface that ships in ForgeOS Method today.
BühlerVision, a white-labeled connected-worker product, branded by Bühler, built by our team.
Bühler Group, the global leader in food and feed processing equipment, selected our team to build the customer-facing experience layer for BühlerVision, their flagship remote service offering. Bühler positioned it under their own brand. The product remains in active use as part of Bühler's global service standard.
Bühler press release →Underlying connected-worker engine licensed from Ubimax/TeamViewer Frontline. Customer-facing product experience and integration delivered by our team.Smart glasses for service technicians, deployed across BMW of North America's U.S. dealership network.
Our team led the original smart-glasses deployment to BMW of North America's U.S. dealership network and the 2023 device refresh that introduced new hardware to the dealership fleet.
BMW Group press release →Service-technician deployment at BMW dealerships, not BMW manufacturing operations. Underlying smart-glasses platform licensed from Ubimax/TeamViewer.Vision Picking, the world's largest industrial smart-glasses deployment.
Our team led implementation across DHL Supply Chain sites globally, with multi-site deployments running as recently as 2024.
Supply Chain Digital article →Underlying Vision Picking product licensed from Ubimax. Our team led implementation, integration, and operational rollout.Digital work instructions deployed at Unipres, a Tier 1 automotive stamping supplier.
Unipres, a Tier 1 automotive stamping and forming supplier, runs digital work instructions our team deployed for their assembly and production operations. The platform shares its codebase lineage with the authoring and delivery layer that ships in ForgeOS Method today.
Two further deployments, in industrial equipment and precision machining, are counted toward the seven and are not named here.
What ForgeOS Method actually does.
Three things. Each one earns its place against a real pain a Director of Ops named this week.
Playing 1 of 4 · Start
Author once, in any format you have.
Engineering hands you a CAD file and a PDF spec. The senior operator on Line 2 does the build the right way and you record three minutes of video. ForgeOS Method turns those three inputs into a structured work instruction in minutes, ready to revise and push to the floor.
PDF, CAD, video, voice recording. Author from whatever you actually have, not whatever a software vendor wishes you had. Digital work instructions and paperless work instructions start here.
Quality built in, not bolted on.
SPC checkpoints at the operator step. Non-conformance reports created from the line, with the WI revision and the operator's last action attached automatically. The audit trail builds itself.
Most WI tools stop at “show the operator the right step.” ForgeOS Method closes the loop. When the floor finds an issue, it routes back to a WI revision suggestion. Same defect does not happen again three months later.
Bundled hardware. Public pricing. No minimums.
$1,000 per month, unlimited users. Annual prepay at $12,000 includes two RealWear HMT-1 smartglasses at no additional cost. Additional devices $397 each. Software pricing on this page, not behind a “talk to sales” wall.
Tulip's floor is $1,000 a month with a 10-interface minimum, billed per station. Dozuki starts at 50 users. ForgeOS Method starts at one operator and one work instruction, unlimited users at every tier.
| ForgeOS Method | Tulip | Dozuki | |
|---|---|---|---|
| Monthly price | $1,000/mo | $1,000+/mo | Quote |
| Per-station / user minimum | None | 10 interfaces | 50 users |
| Unlimited users | ✓ | ✗ | ✗ |
| Hardware bundled | ✓ ($397 ea) | ✗ | ✗ |
| Public pricing | ✓ | ✗ | ✗ |
What digital work instructions are worth on a 50-person plant.
Plain math. No “AI savings” claims. The numbers that show up on your operating review.
1 point of OEE on a $30M plant
$200K to $400K per year
Most plants in the 50 to 150 employee range run at 65 to 72% OEE. A current-revision work instruction at the operator's point of work, with quality checkpoints built in, does not fix every OEE loss. It does take the WI-revision-lag bucket and the operator-error bucket off the table. That is typically 1 to 3 points.
4 weeks to 1 week of new-hire ramp, on six new hires per year
$30K to $60K saved
Voice-driven, scan-validated, video-clear work instructions on industrial smart glasses change the labor model for new hires. Senior operators stop being shadow trainers full-time. New hires hit standard cycle time in week one.
Avoiding one customer line-down event during launch
$50K to $200K, depending on the customer
Whatever you are launching this year needs dozens of new work instructions, training plans, and capability studies on a customer-imposed deadline. Manual authoring in Word does not scale. Authoring from CAD, video, PDF, or voice does.
One avoided IATF 16949 major finding
$25K direct cost, plus the customer relationship value you cannot price
Single source of truth for work instruction revisions. Training records tied to the right revision. Capability data tied to the right work instruction. Three clicks to show an auditor what they are asking for.
Pricing. On the page.
Start with a pilot on one line. Expand when it earns it.
Launch Pilot
$2,500 one time
Six weeks on one production line, run with your team.
- ✓Six weeks, one production line
- ✓Up to ten work instructions authored with your team
- ✓Two RealWear HMT-1 headsets included
- ✓The full $2,500 credits toward your first annual if you continue
After the pilot
The $2,500 credits in full toward your first annual.
Method Annual
$12,000/ year
Includes two RealWear HMT-1 smartglasses. Additional headsets $397 each.
Method Monthly
$1,000/ month
Headsets $397 per unit.
- ✓Unlimited users
- ✓Unlimited work instructions
- ✓All software features included
- ✓No minimums, no per-seat math
Quick Start
Multi-site rollouts and integration with the systems you already run.
Questions before you start.
The Launch Pilot is a fixed $2,500 engagement over six weeks on one production line. It includes up to ten work instructions authored with your team and two RealWear HMT-1 headsets. The full $2,500 credits toward your first annual plan if you continue. It is one invoice rather than a subscription commitment, which makes it a smaller first decision than a full rollout.
ForgeOS Method has no minimum operator count, no minimum user count, and no minimum number of work instructions. The monthly plan starts at $1,000 with unlimited users. If you have one line and one process worth documenting, a Launch Pilot is the place to start. Most of our target customers are in the 30 to 150 employee range.
Tulip starts at $1,000 per month with a 10-interface minimum, meaning you are paying for 10 stations whether you use them or not. ForgeOS Method is $1,000 per month for unlimited users with no per-station fees. Tulip does not bundle hardware. ForgeOS Method includes two RealWear HMT-1 smartglasses with the annual plan and sells additional units at $397 each. Tulip is a strong product for large deployments. ForgeOS Method is built for manufacturers who want to start on one line and expand without repricing.
No. A Launch Pilot is designed to be run by an operations manager or manufacturing engineer without IT involvement. We ship pre-configured RealWear devices, author the first work instructions with your team, and you continue in the browser. If you need integration with your MES, ERP, or PLC stack, that is what the Quick Start engagement covers, and we handle the integration work, not your IT team.
Computer vision is available as an integration in the Quick Start tier, not included in the base subscription. ForgeOS Method connects to existing computer vision systems you already have deployed. We do not bundle a CV inference engine in the base product. If you are evaluating CV for quality inspection alongside work instructions, mention it on the Quick Start call.
The annual plan at $12,000 per year includes two RealWear HMT-1 smartglasses at no additional cost. If you need more devices, additional units are $397 each, the same price we sell them at regardless of quantity. There is no volume minimum for additional hardware. Devices ship pre-configured from our office. If you are on the monthly plan and want to add hardware, you can purchase devices separately at $397 each at any time.
Quick Start is our assisted deployment tier for manufacturers who need integration with existing systems, multi-site rollouts, or a faster path to full deployment. It includes integration with your MES, ERP, CMMS, PLC stack, and computer vision systems if applicable. You get a dedicated success manager and a deployment timeline matched to your launch schedule. Pricing is quoted based on scope. Book a Quick Start call to get a scoped estimate.
Work instruction content, operator interaction data, and quality checkpoint records are stored in ForgeOS Method's cloud infrastructure hosted on AWS US regions. If your operation requires data to stay on-premise, whether that is an air-gapped facility, a defense contractor, or a CMMC requirement, that is handled through the ForgeOS Platform on-premise deployment, not ForgeOS Method. For most manufacturers, the cloud deployment meets their data requirements. Specific data handling questions can be addressed on the Quick Start call or by emailing info@newforgetech.com.
New to digital work instructions? Read the complete guide: What Are Digital Work Instructions in Manufacturing? →
Your next product launch does not have to be a fire drill.
Digital work instructions running on the floor in days. Authored from CAD, video, PDF, or voice. Voice-driven on industrial smartglasses. Quality built into the step. Audit trail that builds itself.
Launch Pilot, $2,500. Six weeks on one line, run with your team.