Heat H-2208 · SG 500/7 · Furnace F2
1,482°CTapping
Est. 2022 · Foundry & manufacturing software
Software built on the foundry floor, for the foundry floor.
BAAS Soft Systems builds Smart Factory OS and a suite of shop-floor apps that take a casting from enquiry to dispatch, with every heat, spectro reading, calibration and invoice accounted for.
16products, one data model
4,400+part masters imported in one PMS rollout
1,500+employees on a single payroll deployment
0.00%variance against the spreadsheets we replaced
Spectro · Sample 2 vs grade spec
| C | 3.42 | 3.30–3.60 |
| Si | 2.31 | 2.20–2.60 |
| Mn | 0.19 | 0.20–0.35 |
| Mg | 0.041 | 0.035–0.055 |
| S | 0.009 | ≤ 0.015 |
Delay intelligence · Orders at risk
SO-1204 · Ball valve 8" RF92% Critical
SO-1212 · Check valve 10"61% Reroute
SO-1216 · Butterfly 14" lug8% MTC issued
Casting gate · Machining release
PO-1200 · Gate valve 12"Waiting fettling
PO-1228 · Needle valve 2"Released · op 20
CNC-01 queue6 jobs · 14.5 h
Traceable to heat → pour → inspection → MTC
Illustrative demo data
EnquiryRFQ · Costing
PlanOrders · Routing
MeltHeats · Spectro
Mould & pourJobs · Yield
MachineSchedule · MES
InspectGauges · NCR · MTC
DispatchGST e-invoice · e-way
AccountTally · Payroll
Flagship · Smart Factory OS
One system from sales order to shop floor.
Smart Factory OS connects every sales order to heats, machines and inspections in one database. Planners see which orders will slip before they do, machining is scheduled only when castings are actually ready, operators work from scan-to-complete screens, and quality closes the loop with NCR disposition and downloadable test certificates traceable back to the pour.
01Dashboard
02Delay intelligence
03Planning
04Scheduler
05Foundry
06MES
07Quality & MTC
08Capacity · Energy · AI
Delay intelligence
Every open order carries a live delay-risk score recomputed from schedules, foundry status and machine load. The score is explained, not just displayed.
- Six factors machine load · queue depth · routing complexity · foundry delay · downtime history · material readiness
- Output the bottleneck and a recommended action, e.g. overtime on CNC-01
- Recompute on demand or on every refresh
Finite-capacity scheduler
Drag-and-drop planning with real constraints enforced by the server. Impossible plans are rejected before they reach the floor.
- No overlaps same machine, same time is refused
- Shift windows blocks outside 06:00–22:00 are refused
- Casting gate rough turn cannot be scheduled until fettling releases the casting
- Alternate routings reroute recommendations when a machine is overloaded
Foundry to certificate
Heats, pours and fettling feed machining. Inspection, NCR disposition and certificates close the loop with full genealogy.
- Heat link every production order knows its heat and pour
- MES operators scan to start and complete operations
- NCR disposition with rework, use-as-is or scrap
- MTC material test certificates generated per order
Connects to
Microsoft Dynamics NAV / Business Central via OData
Foundry ERP & Foundry PMS
Spectro Analysis
BAAS-IOT machine signals
Tally via TallyBridge
Product suite · 16 applications
Every product owns one stretch of the order path.
Each application runs on its own, and each shares the same conventions: PostgreSQL underneath, role-based access, audit trails, Excel and PDF out, and QR or RFID identity where a physical thing needs a digital twin. Deploy one, or deploy the suite.
Plan & produce
Orders, jobs, heats and schedules
SFOSAI
Smart Factory OS
The foundry-to-dispatch MES and planning layer: delay intelligence, finite-capacity scheduling with a casting gate, operator MES, quality and MTC.
- Order-level delay risk with six explained factors
- Server-enforced scheduler constraints
- Heats, pours, fettling and release to machining
- Scan-to-complete operator screens
- Inspection, NCR disposition, test certificates
- Capacity, energy and AI reroute recommendations
- Dynamics NAV OData integration
- Boardroom dashboard on the same live data
FND-ERPLive
Foundry ERP
End-to-end foundry production and business management with statutory GST invoicing built in.
- Tax invoices with gap-free numbering per financial year
- Automatic e-invoice IRN and e-way bill, QR on the PDF
- Location-aware stores: per-unit and per-stage WIP stock
- Melting, moulding, core, fettling and rejection KPIs
FND-PMSLive
Foundry PMS
Production management for multi-unit foundries. Replaced eight spreadsheets at a three-unit plant.
- Jobs move Planned → Moulded → Poured → Completed
- Heats with charge mix, metallic yield and spectro chemistry
- EN 10204 3.1 certificates, auto-numbered PDF
- Orders, dispatch register, vendors, outsourcing, daily shop report
MSSModule
Machine Shop Scheduling
The Smart Factory OS scheduler as a standalone module for machine shops that buy castings in.
- Finite-capacity Gantt per machine
- Routing and alternate routing per part
- Queue depth and utilisation dashboards
Melt & quality
Chemistry, gauges, complaints and drawings
SPECTROAI
Spectro Analysis
Reads spectrometer results per heat, compares them to the grade specification and recommends the cheapest correction.
- Lab-PC connector ingests every spark automatically
- Optimiser computes the lowest-cost in-spec addition mix
- AI writes step-by-step furnace instructions; it never invents quantities
- Big-screen melt-shop monitor, CSV and print reports
MCMSLive
Metrology & Calibration
The full life of every measuring instrument, from master record to retirement.
- QR and RFID identity, scan on the shop floor
- Calibration schedules and work-order execution
- Reading capture with measurement-uncertainty maths
- Internal certificates, gauge issue and return, XLSX reports
CMSLive
Complaint Management
Customer complaints captured, routed and closed with a proper 8D.
- Email intake creates complaints automatically
- 8D discipline by discipline, FMEA and control-plan documents
- Customer-specific report templates, PDF and Excel
- Microsoft 365 sign-in
QMSSuite
Quality Management
Inspection plans, in-process and final QC, and the compliance records auditors ask for.
- In-process and final inspection with auto QC certificates
- Document control for ISO audits
- Rejection analysis by stage and cause
AUTOBALLOONAI
AutoBalloon
Upload a 2D engineering drawing and get numbered balloons, a characteristics list and inspection documents.
- Vector PDFs read exactly; scans go through OCR plus vision AI
- Inspection plans, AS9102 FAI forms, control plans, PFMEA
- Multi-tenant SaaS, drawing revisions tracked
BAAS-IOTHardware
BAAS-IOT Edge Controller
An industrial PoE controller that puts machine and sensor signals into the same database as your orders.
- 8 isolated digital inputs, 8 relay outputs, RS485 Modbus, 4–20 mA
- Ethernet with Wi-Fi failover, MQTT to PostgreSQL
- UHF RFID reads for tote and pattern tracking
Sell, staff & secure
Enquiries, people and the gate
RFQAI
RFQ Management
Enquiries arrive by email and become draft RFQs on their own, then flow through costing, quotation and new-product development.
- Mailbox polling; AI reads the body, PDFs and images
- Low-confidence extractions flagged for human review
- Costing versions and quotes per RFQ
- APQP stage board for awarded new parts
PAYROLLLive
Payroll & Attendance
Attendance from biometric devices to approved payroll, for monthly, weekly and contract workers alike.
- Direct sync from Hikvision access-control terminals
- Piece-rate and contract daily production pay
- Advances, recoveries, bonuses, perks and statutory deductions
- MD executive overview; proven at 1,500+ employees
FACTORYMEETAI
factoryMeet
Meeting intelligence for plants: record with consent, transcribe live, and turn talk into tracked actions.
- Live transcription in English, Tamil and code-switched speech
- AI minutes with decisions, risks and action owners
- Ask questions across every past meeting
- Action-closure reports by department
SEC-GATESuite
Security Gate
Gate entry, visitor passes and material movement control at the plant boundary.
- Visitor and vehicle register with photo capture
- Returnable and non-returnable gate passes
- Ties inward material to purchase orders
Account & vertical ERPs
Books, textiles and garments
TALLYBRIDGEAI
TallyBridge
An on-premise utility that talks to TallyPrime over its XML gateway and does the accountant's three hardest jobs.
- Fills the government Balance Sheet and P&L Excel template from the trial balance
- GSTR-2B reconciliation against the purchase register
- Supplier invoice OCR to Purchase voucher, with human review
FINISHFLOWVertical
FinishFlow Textile ERP
Smart finishing ERP for dyeing and finishing units, built around QR roll traceability.
- Configurable routing per order, drag-and-drop
- Scan-to-start and complete on every process
- Roll genealogy, QC certificates, packing, dispatch challans
GARMENTSVertical
Garments ERP
Order-to-shipment ERP for export garment manufacturers, from fabric sourcing to packing list.
- Fabric plans with mill rules and process loss
- Style, size and colour breakdowns
- Production, quality and shipment tracking
AI on the floor
AI where it saves a shift, never where it guesses a number.
We use large language models to read documents, drawings and speech, and deterministic engines to compute anything that ends up on a certificate or an invoice. Every AI call is logged, and anything below a confidence threshold is routed to a person.
R
Email to RFQ
RFQ Management polls your enquiry mailbox, reads the body and attached drawings, and creates a draft RFQ with parts, quantities and dates. Anything under 70% confidence waits for review before it enters the pipeline.
S
Spectro correction
An optimiser computes the cheapest addition that brings the heat into specification. The AI layer adds grade knowledge and writes the furnace instructions in plain language. The quantities come only from the optimiser.
B
Drawing ballooning
AutoBalloon combines OCR with vision AI to find every dimension, tolerance and note on a drawing. A deterministic parser is the only source of numeric truth; the AI re-reads ambiguous regions and is capped when uncorroborated.
M
Meeting minutes
factoryMeet transcribes review meetings live, including Tamil and English in the same sentence, then extracts decisions, risks and action items with owners and due dates. Recording only starts after a logged consent.
Models run server-side. API keys never reach a browser, and we can run on Anthropic Claude or OpenAI depending on your data policy. Deterministic mock providers ship with every product so you can test the workflow offline.
Platform & integrations
Boring technology, deliberately.
Every product runs on the same stack so one team can support all of them, and so your IT department is never surprised. On-premise on a plant server, on our managed VPS, or on your cloud account.
| Layer | What we use |
|---|---|
| Database | PostgreSQL, one schema per product, nightly dumps, point-in-time restore on request |
| Backend | Node.js with Express or Fastify, typed APIs, role-based access, Zod validation, audit logs |
| Web app | Vue 3 with Vuetify, tablet-first layouts, works in landscape on the shop floor |
| Mobile | Capacitor builds for Android where scanning is the primary job |
| Documents | PDF certificates and invoices, Excel imports and exports, QR labels |
| Hosting | On-premise Windows or Linux, managed VPS with SSL, or AWS single-box |
| AI providers | Anthropic Claude, OpenAI; pluggable, server-side only |
| Integration | How it connects |
|---|---|
| Dynamics NAV / BC | OData reads for orders, items and routings; SOAP codeunit write-back for stage completion |
| TallyPrime | HTTP-XML gateway on the LAN; vouchers pushed idempotently |
| GST portal | e-invoice IRN and e-way bill through a GSP adapter, with a sandbox provider for testing |
| Attendance devices | Hikvision ISAPI event polling for terminals and canteen readers |
| Spectrometers | Lab-PC connector watches result exports and posts each spark |
| Machines & sensors | BAAS-IOT controller over MQTT: digital, analog, Modbus RTU, RFID |
| Identity | Microsoft 365 sign-in or local accounts with roles |
Industries
Built in Coimbatore's industrial belt.
Our first customers were foundries and the machine shops that buy from them. The same discipline now runs in textile finishing and garment export plants.
Foundries
Grey and SG iron, steel and non-ferrous. Heats, chemistry, yield, rejection and certificates in one place.
Foundry ERP · Foundry PMS · Spectro · SFOSValve & machine shops
Casting-dependent machining with finite-capacity scheduling and traceability to the heat.
SFOS · MSS · MCMS · AutoBalloonTextile finishing
Dyeing and finishing units that need roll-level traceability from inward fabric to dispatch.
FinishFlow · TallyBridge · PayrollGarment exporters
Style-driven production with fabric sourcing rules, QC and shipment tracking.
Garments ERP · Payroll · Security Gate
About BAAS Soft Systems
A small team that ships in build passes.
BAAS Soft Systems was founded in 2022 to build the software we could not buy for the plants around us. Generic ERPs stop at the office door. We start at the furnace.
Every product began with a real plant problem: a foundry running three units on eight spreadsheets, a melt shop correcting chemistry by memory, a quality department chasing calibration due dates on paper, an accountant re-typing Tally into a government template. We fix one problem completely, verify it against the plant's own numbers, and only then move to the next.
Because all sixteen products share one platform, a customer who starts with payroll can add spectro analysis or the full Smart Factory OS without a migration project.
4,400+part masters and a month of jobs imported and reconciled to the plant's own sheets
0.00%variance between the PMS and the spreadsheets it replaced
1,500+employees paid every month through one payroll deployment
3production units of one foundry running a single PMS
- Walk the floor
We spend the first days at your plant with the people who own the spreadsheets, not in a conference room.
- Blueprint
A written blueprint fixes the data model, roles and reports before code. You sign it; we build to it.
- Build passes
Working software every pass, each verified end-to-end. Your real data goes in early so mistakes surface early.
- Reconcile
We import history and reconcile it against your existing records to the rupee and the kilogram before go-live.
- Go live and stay
Managed hosting or on-premise, with the same engineers who built it answering support.
Contact
Bring us a spreadsheet you want to retire.
Tell us which part of the order path hurts most. We will show you the matching product on your own data, on a tablet, at your plant if you are in Tamil Nadu.
- Phone
- Address10, Thaneer Pandal Road, Peelamedu,
Coimbatore 641004, Tamil Nadu, India - HoursMonday to Saturday, 9:00 to 18:00 IST
- DemoLive demos on request for every product, including Smart Factory OS on Dynamics NAV data