Manufacturing Cost Optimization Digital Worker

Core Logic

Acts as the central coordinator managing the entire workflow lifecycle. Dispatches tasks to specialized agents, aggregates results using weighted synthesis, and makes autonomous optimization decisions based on configurable thresholds. Maintains the inter-agent message bus and ensures workflow phase transitions. Generates four optimization scenarios (cost-optimized, time-optimized, balanced, quality-optimized) by synthesizing all agent outputs.

Core Logic

Parses CAD files using specialized geometry kernels to extract bounding boxes, volumes, and surface areas. Employs feature recognition algorithms to identify manufacturing-critical features: holes, pockets, slots, bosses, ribs, threads, fillets, and chamfers. Performs automated Design-for-Manufacturability (DFM) analysis flagging issues like thin walls, deep pockets, sharp internal corners, and undercuts. Outputs complexity scores and feature-based cost drivers.

Core Logic

Evaluates six manufacturing process families (CNC machining, injection molding, die casting, sheet metal forming, additive manufacturing, joining/assembly) using TOPSIS multi-criteria decision analysis. Scores each process against weighted criteria including geometric compatibility, material constraints, volume economics, and quality requirements. Generates optimal process chains with sequenced operations and identifies secondary processing requirements.

Core Logic

Implements Activity-Based Costing (ABC) methodology calculating costs across seven categories: raw material, direct labor, machine time, tooling amortization, overhead allocation, quality costs, and logistics. Applies learning curve models (typically 85% curve) for volume scenarios. Performs Monte Carlo sensitivity analysis identifying cost drivers with highest impact. Generates cost breakdowns at part, assembly, and product levels with confidence intervals.

Core Logic

Evaluates qualified suppliers using multi-criteria scoring across price competitiveness, quality performance, delivery reliability, technical capability, and financial stability. Calculates Economic Order Quantity (EOQ) and optimal reorder points. Performs supply chain risk assessment including single-source exposure, geographic concentration, and lead time variability. Recommends inventory strategies (JIT, safety stock, VMI) based on demand patterns and supplier reliability.

Core Logic

Creates risk-based inspection plans using FMEA severity and occurrence ratings to prioritize critical-to-quality (CTQ) characteristics. Specifies measurement methods, sampling plans, and acceptance criteria. Analyzes process capability (Cpk/Ppk) requirements and recommends SPC control chart types. Estimates quality costs including inspection time, scrap rates, and rework requirements based on process capability levels.

Core Logic

Calculates carbon footprint using GHG Protocol methodology across Scope 1 (direct process emissions), Scope 2 (purchased energy), and Scope 3 (supply chain) categories. Maps emission factors to materials, processes, and logistics activities. Performs lifecycle assessment from raw material extraction through end-of-life. Identifies carbon reduction opportunities with quantified impact and cost-benefit analysis. Generates ESG performance scores for stakeholder reporting.

Core Logic

Integrates real-time commodity price feeds from LME (metals) and CME (energy, plastics) exchanges. Applies time-series forecasting models to predict price trends over planning horizons. Monitors supply chain risk signals including supplier financial health, geopolitical events, and logistics disruptions. Performs competitive benchmarking against industry cost indices. Generates price volatility alerts and hedging recommendations.

Core Logic

Assesses CBAM applicability based on product categories (iron/steel, aluminum, cement, fertilizers, electricity, hydrogen) and trade flows. Calculates embedded emissions using actual production data or default values per CBAM regulation. Estimates certificate costs based on EU ETS pricing and required surrender volumes. Tracks reporting deadlines and generates compliant declaration documents. Models impact of different supplier choices on CBAM exposure.