FLG-001 — Complete Project Specification
ForgeLogic
Full Scope of Work
AI-Powered No-Code PLC + HMI Platform. Every section, every spec, every deliverable — the complete engineering blueprint for the ForgeLogic product under Hibb Co. LLC.
5
Development Phases
18 mo
Total Timeline
23
Specification Sections
32+
Completion Criteria
Section 1
Product Vision & Market Position
What ForgeLogic Is
A complete PLC replacement unit — custom circuit board with industrial-grade I/O, integrated touchscreen HMI, no-code configuration interface, AI-powered programming via KevAI-OS, and a full machine monitoring and reporting dashboard. It is a single hardware purchase that replaces PLC + HMI + programming software + monitoring system.
What ForgeLogic Is NOT
- Not a PLC add-on or retrofit module (it replaces the existing PLC entirely)
- Not a software-only solution (includes custom hardware with I/O)
- Not limited to a specific industry (works anywhere PLCs work)
- Not a SCADA system (though it includes monitoring features)
- Not dependent on internet connectivity (runs standalone; cloud features are optional)
- Not a toy or hobbyist device (industrial-grade I/O, 12V/24V rated, production environment ready)
The Gap in the Market
Every existing PLC ecosystem — Allen-Bradley, Siemens, Schneider, Mitsubishi — was designed for a world where specialized programmers write code in proprietary languages using expensive licensed software. The entire industry assumes the user can program. ForgeLogic assumes they can’t — and doesn’t need to.
The closest competitor (Unitronics) offers combined PLC+HMI units with simplified programming. But even Unitronics requires their UniLogic software and knowledge of PLC programming concepts. Nobody has built a PLC where the “programming” is done entirely through settings screens and AI.
10 Competitive Differentiators
- Zero-code configuration through touchscreen HMI settings screens
- AI-powered programming via KevAI-OS (describe what you need in English, get working code)
- No proprietary programming software required (no license fees, no software dependencies)
- Built-in machine monitoring, reporting, and analytics
- Multi-machine fleet management through KevAI-OS
- AI-powered optimization recommendations based on operational data
- Programming-as-a-Service revenue model (Hibb Co. programs it for you)
- Mobile device pairing (configure via iPhone/iPad, tap to deploy)
- Machine user login, scheduled lockdown, remote on/off via KevAI-OS
- Lifecycle tracking, maintenance reminders, failure logging with timestamps
Section 2
Market Intelligence Report
Global PLC Market Size
| Metric | Value | Source |
|---|---|---|
| 2025 Market Size | USD $12.66 billion | Fortune Business Insights |
| 2026 Projected | USD $13.45 billion | Fortune Business Insights |
| 2034 Projected | USD $21.83 billion (CAGR 6.20%) | Fortune Business Insights |
| North America 2026 | USD $2.73 billion | Fortune Business Insights |
| Asia Pacific Share | 39.10% ($4.95B) in 2025 | Mordor Intelligence |
PLC + HMI All-in-One Market (ForgeLogic’s Direct Segment)
| Year | Value | Source |
|---|---|---|
| 2025 | ~$2 billion | DataInsightsMarket |
| 2026 | $3.8 billion (9.2% CAGR) | IndustryARC |
| 2033 | $5.9 billion (8% CAGR from 2025) | DataInsightsMarket |
AI in Industrial Automation
- Beckhoff: TwinCAT CoAgent generates PLC code via AI assistant (shown at SPS 2025)
- Schneider Electric: EcoStruxure Automation Expert with AI agents generating PLC applications from user specifications
- Siemens: AI integration into TIA Portal for predictive maintenance
Key insight: The majors are bolting AI onto existing complex platforms. Nobody is building AI-native from scratch for the non-programmer user.
Target Market Segments
- Small-to-mid manufacturers with aging PLCs who can’t afford $10K+ for new Allen-Bradley systems + programming
- Maintenance/facilities departments that need to replace failed controllers without hiring a PLC programmer
- OEM machine builders looking for lower-cost controller solutions for their equipment
- Industrial integrators (like Jason) who service machines and need fast, affordable replacements
- Food/beverage, packaging, HVAC, water treatment — industries with many small-to-medium machines running simple I/O logic
Competitor Hardware Pricing
| Manufacturer | Entry | Mid-Range | High-End | Software |
|---|---|---|---|---|
| Allen-Bradley | $1,000 | $3,500 | $5,000+ | $500+ (Studio 5000) |
| Siemens | $500 | $1,500 | $2,000+ | $500+ (TIA Portal) |
| Schneider | $400 | $1,200 | $2,000+ | EcoStruxure license |
| Unitronics | $500 | $1,200 | $2,500+ | FREE (UniLogic) |
| AutomationDirect | $300 | $800 | $1,500+ | FREE |
| EZAutomation | $400 | $900 | $1,500+ | FREE |
ForgeLogic target price point: $1,500–$3,000 (hardware + HMI + built-in software, no additional license fees). Premium over Unitronics justified by zero-code setup, AI integration, and built-in monitoring/reporting.
Section 3
Competitive Landscape
Tier 1 — Enterprise PLCs (The Dinosaurs ForgeLogic Replaces)
Allen-Bradley / Rockwell Automation
Market leader in North America. ControlLogix and CompactLogix lines. Massive install base, excellent support ecosystem, long-term parts availability, industry trust. Weaknesses: Premium pricing ($1K–$5K+ hardware, $500+ software). Requires trained PLC programmers. Proprietary ecosystem lock-in. Overkill for simple I/O applications. ForgeLogic angle: Direct replacement for aging Allen-Bradley SLC 500 and MicroLogix units in the field.
Siemens
Market leader in Europe. S7-1200 and S7-1500 lines. Excellent engineering, TIA Portal integration. Weaknesses: Similar pricing to Allen-Bradley. Complex programming environment. ForgeLogic angle: Same replacement opportunity for aging S5 and early S7-300 systems.
Schneider Electric
Modicon M221 (entry) through M580 (high-end). Broader price range, EcoStruxure platform vision, recent AI integration. Weaknesses: Smaller North American support network. ForgeLogic angle: Their AI agent features validate the market direction but they’re bolting AI onto complexity. ForgeLogic starts simple.
Tier 2 — Combined PLC+HMI (Closest Competitors)
Unitronics
Closest competitor. Samba, Vision, and UniStream lines combine PLC + HMI in one unit. UniLogic software is FREE. Cloud services (UniCloud) included. Weaknesses: Still requires PLC programming knowledge. No AI integration. Limited monitoring/analytics. ForgeLogic angle: Unitronics proved the market wants combined PLC+HMI. ForgeLogic eliminates the programming step entirely.
EZAutomation (EZTouchminiPLC)
Budget-friendly combined PLC+HMI. Low cost, simple feature set, U.S.-based. Weaknesses: Limited I/O, limited scalability, still requires programming.
AutomationDirect (Click PLC + C-more HMI)
Separate but paired PLC and HMI products. Very competitive pricing, excellent documentation. Weaknesses: Two separate products. Programming required.
Tier 3 — IIoT/SCADA Monitoring Platforms
Ignition by Inductive Automation
Leading SCADA/MES platform. Unlimited licensing model, powerful visualization, IT/OT convergence. Requires separate PLCs. Enterprise-focused pricing.
MachineCDN
Cloud-native IIoT platform. Edge device plugs into existing PLC, streams data to cloud in minutes. Fastest deployment (3 minutes). Monitoring only — doesn’t replace the PLC.
ThingsBoard
Open-source IoT platform. 600+ dashboard widgets. Highly customizable. Requires technical setup. Not industrial-specific out of the box.
No competitor combines ALL of these in a single product: PLC replacement hardware, integrated HMI, zero-code configuration, AI programming, built-in monitoring, fleet management, AI optimization, and Programming-as-a-Service. The closest experience is Unitronics hardware + MachineCDN monitoring + a PLC programmer. ForgeLogic replaces all three.
Section 4
Architecture & Hardware Design
Custom Circuit Board Specification
I/O Requirements
- 12V and 24V input/output support (dual voltage, configurable per pin)
- Minimum 8 digital inputs, 8 digital outputs (expandable via I/O modules)
- Minimum 4 analog inputs (A-to-D for pressure, temperature, flow sensors)
- Minimum 2 analog outputs (D-to-A for variable-speed drives, proportional valves)
- All I/O optically isolated for industrial noise immunity
- Screw terminal connections (industry standard)
Processing
- Industrial-grade ARM or ESP32-based microcontroller (ruggedized, wide temperature range)
- Real-time operating system (RTOS) for deterministic I/O scan times
- Non-volatile storage for configuration persistence (survives power loss)
- Watchdog timer for safety (auto-restart on lockup)
Communication
- Ethernet (10/100) for KevAI-OS connection, remote monitoring, fleet management
- WiFi (optional module) for mobile device pairing
- Bluetooth LE (optional) for tap-to-configure from mobile device
- RS-485/Modbus RTU for legacy device communication
- USB port for local configuration backup/restore
HMI Integration
- 7″ or 10″ capacitive touchscreen (hardened glass, industrial-rated)
- Minimum 800x480 (7″) or 1024x600 (10″) resolution
- Sunlight-readable display option, IP65 front panel rating
- DIN rail or panel mount options
Power
- 24VDC input (industrial standard)
- Internal voltage regulation for 12V and 3.3V rails
- Surge/transient protection (industrial environments are electrically noisy)
- Battery backup for real-time clock and configuration retention
Software Architecture (5-Layer Stack)
1
HMI Application (Touchscreen UI)
Settings screens, rule builder, dashboards, reports. Built on embedded Linux + lightweight UI framework. This is what the user sees.
2
Configuration Engine
Translates user settings into executable I/O logic. If/then rule compiler, pin assignment manager, analog threshold engine, timer/counter management.
3
Real-Time I/O Engine (RTOS)
Deterministic scan cycle. Reads inputs, evaluates compiled logic, writes outputs. Data logging. Watchdog timer. Safety interlocks.
4
Communication Layer
Ethernet/WiFi/BLE/Modbus. KevAI-OS MCP connector. REST API for remote access. MQTT for fleet telemetry. OTA firmware updates.
5
Data & Reporting Engine
Local SQLite database for I/O logs, run counts, timestamps, user sessions, failures. Generates reports for on-screen display and email export.
Section 5
No-Code HMI Configuration System
This is the core product innovation. The user never writes code. Every configuration action happens through touchscreen settings screens.
Pin Assignment Screen
- Visual pin-out diagram of the controller board
- Tap any pin → dropdown: Input / Output / Analog In / Analog Out / Disabled
- For analog pins: set range (0-10V, 4-20mA), assign unit label (PSI, °F, GPM, etc.)
- Visual confirmation: pin lights up green (input), red (output), blue (analog)
- Duplicate detection: warns if pin assignment conflicts with existing rules
Rule Builder (Visual If/Then Logic)
No text-based programming. All rules built through touch-friendly UI elements.
- Rule structure: IF [condition] THEN [action] (with optional ELSE)
- Conditions from dropdowns: “Pin 4 is HIGH,” “Analog 1 ABOVE [value],” “Timer 1 ELAPSED,” “Counter 1 REACHED [value]”
- AND / OR combinators for complex conditions
- Actions from dropdowns: Set Pin HIGH/LOW, Set Analog Out, Start Timer, Increment Counter, Send Alert, Log Event
- Rules displayed as visual cards, drag to reorder priority
- Toggle rules on/off without deleting them
- Test mode: simulate inputs and watch outputs change in real-time
Timers and Counters
- Named timers (on-delay, off-delay, retentive) and named counters (up, down, up/down)
- Configure through simple numeric fields: duration, target count, reset conditions
- Visual status on dashboard: running, elapsed, count value
Safety and Verification
- Double-check system (Jason’s requirement): simulation shows expected I/O behavior before deployment
- Conflict detection: warns if rules contradict each other
- Dry-run mode: execute logic against simulated inputs for 60 seconds before going live
- Revert button: instant rollback to last known-good configuration
- Configuration versioning: every change saved with timestamp and user ID
Section 6
KevAI-OS Integration
This is where ForgeLogic becomes revolutionary. KevAI-OS turns ForgeLogic from a “simplified PLC” into an “intelligent PLC.”
How It Works
- Machine Documentation Import: Customer imports all documentation — manuals, wiring diagrams, existing PLC code exports, sensor specs, operational procedures. KevAI-OS classifies, indexes, and stores everything.
- Knowledge Base Build: KevAI-OS processes all imported documentation and builds a comprehensive understanding of the machine.
- Natural Language Programming: The technician describes what they need in plain English. Example: “This machine has a hydraulic press. Pin 1 is cycle start, Pin 2 is safety interlock. Analog 1 reads pressure (4-20mA, 0-3000 PSI). Press should cycle down when start is pressed AND safety is clear, stop if pressure exceeds 2500 PSI.”
- AI Code Generation: Claude analyzes the request against imported documentation, generates the complete ForgeLogic configuration — pin assignments, rules, thresholds, timers, safety interlocks.
- Deploy: Configuration exported as a ForgeLogic config file. User taps to load via mobile, Ethernet, or USB.
Three Service Tiers
Tier 1 — Self-Service (Free with Hardware)
User configures ForgeLogic directly through the HMI touchscreen. No AI, no KevAI-OS required. Full feature set of settings screens, rule builder, monitoring.
Tier 2 — AI-Assisted (KevAI-OS Subscription)
Connect ForgeLogic to KevAI-OS instance. Import machine documentation into vault. Claude generates configurations from natural language. Monthly subscription as part of KevAI-OS Pro tier.
Tier 3 — Done-For-You (Programming-as-a-Service)
Customer sends machine documentation and requirements to Hibb Co. We import into KevAI-OS, generate configuration via Claude, review, validate, and ship back. Per-job pricing ($200–$1,000+). Premium turnaround: 24–72 hours. Recurring revenue.
Documentation That Gets Imported
- Existing PLC code exports (ladder logic, structured text, function blocks)
- Wiring diagrams and schematics
- Sensor specification sheets and actuator/valve/motor datasheets
- Machine operator manuals and maintenance procedures
- Safety interlock documentation
- Previous programming notes or change logs
Section 7
Graphical Reporting & Monitoring System
ForgeLogic is not just a controller — it’s a data platform for the machine it controls.
Real-Time Dashboard (On-Screen)
- I/O State Display: Live view of every input and output — graphical HIGH/LOW state, analog values with gauges/bar charts
- Run Counter: How many times each output has fired, how many cycles the machine has completed
- Sensor Readings: Real-time analog values with trend lines (last hour, last shift, last day)
- Active Rules: Which rules are currently evaluating TRUE, which outputs are being driven
- System Health: Controller temperature, uptime, memory usage, communication status
Historical Reporting
- I/O Activity Log: Timestamped record of every input/output change, every analog threshold crossing
- Run Reports: Total machine cycles per shift/day/week/month, average cycle time, max/min
- Sensor Trending: Historical analog data graphed over configurable time ranges
- User Session Log: Who logged in, when, what changes they made
- Failure Log: Every I/O failure, communication loss, watchdog reset, power interruption — timestamped and categorized
Automated Alerts and Reminders
- Maintenance Reminders: Based on run count or calendar schedule
- Lifecycle Tracking: Total runtime hours, total cycles, component wear estimation
- Failure Alerts: Immediate notification on I/O failure, sensor out-of-range
- Scheduled Lockdown: Machine auto-disables at configured times
- Update Reminders: Firmware update notifications, configuration review reminders
Report Delivery Methods
- On-Screen: Full graphical dashboard on ForgeLogic touchscreen
- Email: Scheduled daily/weekly/monthly PDF reports
- KevAI-OS Dashboard: Real-time data feeds for centralized monitoring
- API Export: REST API endpoints for integration with existing plant systems
- Mobile: Push notifications for alerts
Section 8
Multi-Machine Fleet Management
Centralized Monitoring via KevAI-OS
- Single KevAI-OS dashboard showing all connected ForgeLogic units
- Map view (plant floor layout) with machine status overlays
- Color-coded status: green (running), yellow (idle), red (faulted), gray (offline)
- Drill into any machine for detailed I/O state, reports, and configuration
Cross-Machine Comparison
- Efficiency: Machine A vs. Machine B — cycles per hour, downtime
- Lifecycle: Component life comparison, maintenance frequency
- Configuration: Same machine type, different configs — which produces better results?
- Cost-Per-Cycle: Factor in maintenance costs, downtime, energy consumption
Fleet Configuration Management
- Push configuration updates to multiple machines simultaneously
- Version control: see which config version each machine is running
- Staged rollout: update one machine, verify, then push to fleet
- Configuration diff: compare settings between any two machines
Section 9
AI-Powered Optimization Engine
ForgeLogic doesn’t just monitor — it learns and recommends.
What the AI Analyzes
- Cycle time patterns and variations
- Sensor data trends (pressure decay, temperature drift, flow changes)
- I/O failure frequency and patterns
- Maintenance event correlation with operational changes
- Cross-machine performance differences
- Energy consumption patterns (if metered)
- Operator behavior patterns (shift-to-shift variations)
What the AI Recommends
- Timing Optimizations: “Reducing press hold timer from 3.0s to 2.4s would increase throughput by 8% without affecting quality.”
- Maintenance Predictions: “Machine 2’s bearing is showing early degradation. Recommend replacement in next maintenance window.”
- Configuration Changes: “Pressure alarm threshold at 2,800 PSI but has never exceeded 2,300 PSI. Suggest lowering to 2,500 for earlier fault detection.”
- Efficiency Gains: “Machine 4 uses 1.2s delay between cycles vs Machine 1’s 0.5s. Standardizing would increase output by 15%.”
Never auto-applies recommendations — always requires human approval (safety-critical systems).
Section 10
Service Model & Revenue Streams
| Stream | Model | Price Range | Margin |
|---|---|---|---|
| Hardware Sales | One-time purchase | $1,500–$3,000/unit | 40–60% |
| AI Programming Service | Per-job fee | $200–$1,000/machine | 80%+ |
| KevAI-OS Pro (AI features) | Monthly subscription | $12–$18/mo | 90%+ |
| Fleet Monitoring Add-on | Monthly per machine | $5–$15/mo/machine | 90%+ |
| Custom Configuration | Consulting | $150/hr | Variable |
| Training/Certification | Per-student | $500–$2,000 | 70% |
| I/O Expansion Modules | Hardware add-on | $200–$500/module | 40–60% |
Done-For-You Workflow
- Customer contacts Hibb Co. (web form, email, phone)
- Customer provides: machine type, required I/O, desired behavior, existing documentation
- Hibb Co. imports everything into KevAI-OS
- Claude generates ForgeLogic configuration from documentation + requirements
- Hibb Co. engineer (Kevin or Jason) reviews, validates, adjusts
- Configuration file shipped to customer (email or KevAI-OS shared vault)
- Customer loads onto ForgeLogic unit and runs
- Optional: Hibb Co. provides remote support during first commissioning
Turnaround Targets
- Simple machines (< 16 I/O, basic logic): 24 hours
- Medium machines (16–32 I/O, moderate logic): 48 hours
- Complex machines (32+ I/O, multi-sequence logic): 72 hours
- Rush service: 2x pricing for same-day turnaround
Section 11
Mobile & Remote Access
Mobile Device Pairing
- ForgeLogic broadcasts WiFi AP or Bluetooth LE
- Technician walks up with iPhone/iPad, opens ForgeLogic app
- Tap to connect (NFC or QR code scan)
- Full configuration interface on mobile — same as touchscreen HMI
- Deploy new configuration from mobile: drag-and-drop config file
Remote Access via KevAI-OS
- Remote monitoring: see I/O state, sensor data, reports from anywhere
- Remote configuration: push new settings (with safety confirmation)
- Remote on/off: start and stop through KevAI-OS (with authorization)
- Remote lockdown: disable machine remotely for maintenance or security
ForgeLogic Mobile App (Phase 2)
- iOS and Android native app
- Direct connection to ForgeLogic units on local network
- Push notification alerts (faults, maintenance due, threshold crossings)
- Quick-view dashboard for all connected machines
Section 12
Security & Safety
Machine Safety
- Hardware watchdog timer: if software locks up, outputs go to safe state
- Configurable safe states per output (normally open, normally closed, last state)
- Emergency stop input: dedicated hardware input that bypasses all logic
- Configuration change lockout: require physical key switch or authorized login
- Dry-run/simulation mode: test configuration before going live
Access Control
- User login on HMI (username + PIN)
- Role-based access: Operator (view only), Technician (configure), Admin (full access)
- Audit trail: every login, every change, every deployment — timestamped with user ID
- Scheduled lockdown: machine disables at configured times
- KevAI-OS integration: centralized user management for fleet
Data Security
- Configuration files encrypted at rest on the controller
- Encrypted communication between ForgeLogic and KevAI-OS (TLS)
- No cloud dependency for basic operation (all critical functions work offline)
- Configuration backup to USB with encryption option
- Factory reset with secure erase option
Section 13
Pricing & Monetization
Hardware SKUs (Proposed)
| Model | Screen | Digital I/O | Analog I/O | Est. MSRP |
|---|---|---|---|---|
| FL-7 (Entry) | 7″ touch | 8 DI / 8 DO | 4 AI / 2 AO | $1,500 |
| FL-10 (Standard) | 10″ touch | 16 DI / 16 DO | 8 AI / 4 AO | $2,200 |
| FL-10P (Pro) | 10″ touch | 24 DI / 24 DO | 12 AI / 6 AO | $2,800 |
| FL-EXP (Expansion) | N/A | 8 DI / 8 DO | 4 AI / 2 AO | $400 |
Total Cost of Ownership Comparison
Scenario: Replace a failed Allen-Bradley SLC 500 controlling a simple packaging machine
| Cost Category | Allen-Bradley | ForgeLogic |
|---|---|---|
| Hardware | $2,500 (CompactLogix) + $800 (HMI) = $3,300 | $2,200 (FL-10) |
| Software License | $500 (Studio 5000) | $0 (built-in) |
| Programming Labor | $2,000–$5,000 (40–80 hrs) | $0 (self-config) or $500 (Done-For-You) |
| Monitoring System | $2,000+ (SCADA license) or $0 | $0 (built-in) |
| Total | $5,800–$8,800 | $2,200–$2,700 |
| Savings | — | $3,100–$6,100 (53–69%) |
Section 14
User Scenarios
Scenario 1: The Aging PLC Emergency
Jason gets called to a packaging plant. Their Allen-Bradley SLC 500 died. It’s a 1998 install. Nobody has the code. The software to program a replacement (RSLogix 500) is discontinued. A new CompactLogix + Studio 5000 + programmer = $8,000+ and 2 weeks.
With ForgeLogic: Jason pulls a FL-10 off the truck. Opens KevAI-OS on his phone, imports photos of the wiring diagram and I/O list. Claude generates the configuration in 5 minutes. Jason reviews on touchscreen. Deploys. Machine runs. Total time: 2 hours. Total cost: $2,200 hardware + $500 programming service.
Scenario 2: The Non-Programmer Maintenance Tech
A food processing plant has 6 simple conveyor systems each controlled by aging PLCs. The maintenance tech knows the machines inside and out but has zero PLC programming experience.
With ForgeLogic: Replace each PLC with an FL-7. The tech uses touchscreen settings: “Conveyor motor runs when start button is pressed AND safety guard is closed. Stop when stop button is pressed OR jam sensor triggers.” All done through dropdown menus. No code. No programmer. No license fees.
Scenario 3: Fleet Optimization
A bottling plant runs 12 identical filling machines, each with a ForgeLogic FL-10. After 90 days, the KevAI-OS fleet dashboard shows Machine 8 consistently fills 6% fewer bottles per shift. The AI recommendation engine identifies Machine 8’s fill valve close delay is 0.3s longer. One-tap to push the optimized setting. Machine 8 immediately matches fleet performance.
Scenario 4: Done-For-You Service
A HVAC company in Ohio needs to replace the controller on a commercial rooftop unit. They email Hibb Co. the wiring diagram, sequence of operations, and sensor list. KevAI-OS processes everything. Claude generates the full ForgeLogic configuration. Kevin reviews it, confirms safety interlocks, emails the config file. The HVAC tech loads it via USB onto the FL-7 on the roof. Unit runs. Total turnaround: 36 hours. Charge: $400.
Section 15
All 5 Phases — Full Detail
1
Proof of Concept
Months 1–3
Foundation
Hardware
Select microcontroller platform (ESP32-S3 or STM32 for prototyping)
Design prototype I/O board (8 DI / 8 DO / 4 AI / 2 AO)
Select and source touchscreen (7″ capacitive)
Build first functional prototype on breadboard/dev board
PCB design for v0.1 prototype
Software
Embedded Linux or RTOS bring-up on selected platform
Basic HMI framework: pin assignment screen, simple rule builder
I/O scan engine: read inputs, evaluate rules, write outputs
Local data logging (SQLite)
Basic real-time dashboard on HMI
Deliverables
Working prototype that can configure I/O and execute basic if/then logic through touchscreen
Demonstrate: set pin as input, set pin as output, create rule “if input HIGH then output HIGH,” see it work
Video demo for validation
2
Feature-Complete HMI
Months 4–6
Hardening
Hardware
PCB v1.0 fabrication
Industrial enclosure design and sourcing
DIN rail / panel mount options
EMI/EMC testing (basic)
Environmental testing (temperature range)
Software
Full rule builder (AND/OR conditions, timers, counters, analog thresholds)
Full settings screens for all I/O types
Configuration versioning and rollback
Simulation/dry-run mode
Safety interlock logic
Full reporting dashboard (run counts, I/O logs, sensor trending)
User login and access control
Email report generation
USB configuration backup/restore
Deliverables
Feature-complete standalone ForgeLogic unit
No KevAI-OS integration yet — pure touchscreen configuration
Field testing with Jason on 2–3 real machines
3
KevAI-OS Integration
Months 7–9
AI Launch
Software
KevAI-OS MCP connector for ForgeLogic
Machine documentation import pipeline
Claude-powered configuration generation (natural language → config)
Remote monitoring via KevAI-OS dashboard
Remote configuration push
Mobile app (iOS) MVP
Service
Done-For-You programming service launch
Pricing validation with first 10 customers
Service workflow documentation
Deliverables
Full KevAI-OS ↔ ForgeLogic integration working
Natural language programming demonstrated
First Done-For-You service delivered
Mobile app in TestFlight
4
Fleet Management & AI Optimization
Months 10–12
Scale
Software
Multi-machine fleet dashboard in KevAI-OS
Cross-machine comparison analytics
AI optimization recommendation engine
Fleet-wide configuration management (push updates, version control)
Advanced reporting (lifecycle, predictive maintenance, cost-per-cycle)
Hardware
PCB v2.0 (production candidate)
I/O expansion module design
UL/CE certification initiation
Deliverables
Fleet management demonstrated on 5+ units
AI optimization generating actionable recommendations
Production-ready hardware design
Certification in process
5
Production & Launch
Months 13–18
Ship
Production & Certification
Contract manufacturing for PCB and enclosure
UL/CE/FCC certification completion
Production firmware with OTA update capability
Go-to-Market
Sales channel setup (direct, distributor partnerships)
Marketing: website, demo videos, trade show presence
Training/certification program for integrators
Android mobile app
Full documentation and user guides
Section 16
What’s In Scope & What’s Not
In Scope
| Category | Items |
|---|---|
| Hardware Design | Custom PCB (12V/24V I/O), touchscreen integration, enclosure, DIN rail/panel mount, expansion modules |
| Embedded Software | RTOS, I/O scan engine, configuration compiler, data logging, communication stack |
| HMI Application | Pin assignment screens, visual rule builder, timers/counters, simulation mode, dashboard |
| Reporting System | Real-time I/O monitoring, historical logging, run counts, sensor trending, email reports, failure logs |
| KevAI-OS Integration | MCP connector, machine doc import, AI configuration generation, remote monitoring/control |
| Fleet Management | Multi-machine dashboard, cross-machine comparison, fleet configuration management |
| AI Optimization | Data analysis engine, recommendation generation, optimization reports |
| Mobile Access | WiFi/BLE pairing, mobile config interface, push notifications, remote on/off |
| Security | User login, role-based access, audit trail, encrypted config, machine lockdown |
| Services | Done-For-You programming, training program, documentation |
| Certification | UL, CE, FCC testing and certification |
| Manufacturing | PCB fabrication, enclosure, assembly, quality control |
Explicitly Out of Scope (Phase 1)
- High-speed motion control (servo drives, CNC-level positioning)
- Safety-rated PLC functions (SIL-rated, safety PLC certification)
- Support for legacy fieldbus protocols beyond Modbus (Profinet, EtherNet/IP, DeviceNet)
- Cloud-hosted SaaS version (ForgeLogic is hardware-first)
- International distribution (domestic first)
Section 17
MoSCoW Priority Matrix
Must Have — Phase 1–2
Ship or Die
| Feature | Rationale |
|---|---|
| Custom I/O board (12V/24V, DI/DO/AI/AO) | The product IS the hardware |
| Touchscreen HMI with pin assignment screens | Core differentiator — zero-code configuration |
| Visual rule builder (if/then, AND/OR, timers, counters) | Core differentiator — replaces PLC programming |
| Real-time I/O dashboard | Users need to see what the machine is doing |
| Configuration save/load/rollback | Cannot ship without data safety |
| Basic reporting (run counts, I/O logs) | Table stakes for any modern controller |
| Simulation/dry-run mode | Safety requirement — Jason insisted |
| User login and access control | Industrial requirement |
Should Have — Phase 3
Expected by Early Adopters
| Feature | Rationale |
|---|---|
| KevAI-OS MCP connector | The AI angle is the market differentiator |
| Natural language → config via Claude | Eliminates training requirement |
| Remote monitoring via KevAI-OS | Expected for connected devices |
| Email report generation | Requested in original conversation |
| Mobile device pairing (WiFi/BLE) | High user value |
| Machine doc import pipeline | Feeds AI programming capability |
| Done-For-You service workflow | Revenue stream |
Could Have — Phase 4
Delight Features
| Feature | Rationale |
|---|---|
| Multi-machine fleet dashboard | High value for larger customers |
| Cross-machine comparison analytics | Competitive differentiator |
| AI optimization recommendations | “Wow” feature for sales demos |
| Predictive maintenance alerts | Emerging industry expectation |
| Fleet-wide config push | Enterprise-grade management |
| OTA firmware updates | Long-term product viability |
Won’t Have — Descoped
Maybe Future
| Feature | Rationale |
|---|---|
| Safety PLC certification (SIL) | Adds $50K+ in costs and 6+ months |
| High-speed motion control | Different market segment entirely |
| Cloud-only operation | Against core product philosophy (works offline) |
| Legacy fieldbus beyond Modbus | Address when customer demand proves it |
Section 18
9 Risks Identified & Mitigated
| Risk | Prob | Impact | Mitigation |
|---|---|---|---|
| PCB design flaws in v1 | HIGH | HIGH | Multiple prototype revisions budgeted. Use reference designs from MCU vendor. |
| UL/CE certification delays | MED | HIGH | Engage certification lab early (Phase 2). Design to known standards from day one. |
| RTOS reliability issues | MED | HIGH | Use proven RTOS (FreeRTOS or Zephyr). Extensive stress testing. Watchdog timer. |
| Customer resistance to PLC replacement | MED | MED | Lead with cost savings story. Offer trial/demo program. Jason’s field credibility. |
| Supply chain delays (chips, screens) | MED | MED | Dual-source critical components. Stock safety inventory for prototyping. |
| AI-generated configs have errors | MED | HIGH | Human review requirement before deployment. Simulation/dry-run catches logic errors. |
| Competitor copies concept | LOW | MED | Speed to market. AI integration + KevAI-OS ecosystem creates moat. |
| Touchscreen failure in industrial env | LOW | HIGH | Source industrial-rated displays (IP65). Extensive vibration/temperature testing. |
| Pricing too high for target market | MED | MED | Cost analysis against total ownership (not just hardware price). Lead with labor savings. |
Section 19
Technical Dependency Map
ForgeLogic Core
├── Hardware
│ ├── Microcontroller selection → PCB design → Prototype → Production PCB
│ ├── Touchscreen sourcing → HMI integration → Display driver
│ ├── I/O circuitry → Optical isolation → Voltage regulation → Screw terminals
│ └── Enclosure → DIN rail mount → IP rating → Thermal management
├── Embedded Software
│ ├── RTOS bring-up → I/O drivers → Scan engine → Watchdog
│ ├── HMI framework → UI components → Settings screens → Rule builder
│ ├── Configuration compiler → Logic evaluator → Safe state handler
│ ├── SQLite → Data logger → Report generator → Email engine
│ └── Communication stack → Ethernet → WiFi → BLE → Modbus → MQTT
├── KevAI-OS Integration
│ ├── MCP connector → Tool definitions → Authentication
│ ├── Config file format → Import/export → Validation
│ ├── Machine doc import → Classification → Knowledge base
│ └── Claude prompting → Config generation → Verification
├── Fleet Management
│ ├── MQTT telemetry → Cloud broker → KevAI-OS ingestion
│ ├── Fleet dashboard → Machine cards → Comparison views
│ └── Config version control → Fleet push → Staged rollout
└── Certification
├── EMI/EMC testing → FCC Part 15
├── Safety testing → UL 61010 (industrial equipment)
└── EU compliance → CE marking
Section 20
32+ Completion Criteria
Phase 1 Complete When:
Working prototype reads digital inputs and drives digital outputs
Touchscreen displays pin assignment screen and accepts configuration
At least 3 if/then rules can be created and executed through HMI
I/O scan cycle time < 10ms for 16 total I/O points
Video demonstration showing full configuration-to-execution cycle
Jason validates concept on bench setup
Phase 2 Complete When:
PCB v1.0 fabricated and assembled
All I/O types functional (DI, DO, AI, AO)
Full rule builder operational (AND/OR, timers, counters, analog thresholds)
Simulation/dry-run mode working
Reporting dashboard displaying real-time data and historical logs
User login and access control functional
Configuration versioning and rollback working
Email report generation working
Field test on 2–3 real machines (Jason’s job sites)
72-hour continuous operation without fault
Phase 3 Complete When:
KevAI-OS MCP connector operational
Machine documentation imported and searchable in KevAI-OS
Claude generates valid ForgeLogic configuration from natural language
Remote monitoring from KevAI-OS dashboard working
First Done-For-You programming service completed for a real customer
Mobile app connecting to ForgeLogic unit on local network
Phase 4 Complete When:
Fleet dashboard displaying 5+ ForgeLogic units simultaneously
Cross-machine comparison generating meaningful analytics
AI optimization engine producing at least 3 validated recommendations
Fleet-wide configuration push successfully tested
PCB v2.0 design complete and validated
Phase 5 Complete When:
Production run of 25+ units completed
UL certification obtained (or conditional approval)
FCC Part 15 compliance verified
Sales website live with product listings
First 10 units sold to customers outside Jason’s network
Training program delivered to at least 5 integrators
Section 22
7 Key Decisions
2026-04-04
Product name: ForgeLogic
Industrial brand identity — “forge” references metal fabrication (Kevin’s DNA), “logic” references PLC logic replacement. Strong, memorable, domain-available.
2026-04-04
Replace PLC entirely (not retrofit)
Jason confirmed: this is a replacement product, not an add-on. Existing PLCs are “dinosaurs” — the value is eliminating them entirely.
2026-04-04
Dual voltage support (12V + 24V)
Jason specified: “takes in 12 volts and 24 volts.” Covers both common industrial voltage standards.
2026-04-04
KevAI-OS integration as core feature
Kevin’s vision: import machine docs, AI generates configs, no training required. This is the moat.
2026-04-04
Three-tier service model (Self/AI/Done-For-You)
Captures full market: budget-conscious (self-service), tech-forward (AI), and hands-off (service).
2026-04-04
Mobile device pairing
Kevin’s suggestion: “Just walk up to it and tap it and drop in the new code.” Eliminates need for dedicated HMI in some scenarios.
2026-04-04
Double-check/simulation before deployment
Jason’s requirement: verify before going live — “It would have to be accurate enough” to avoid damaging expensive tooling.