Stop Running Your Factory Like It’s 1985.

Your factory might have shiny machines, but if you’re still using outdated spreadsheets or clunky software, you’re stuck in the past. Here’s the truth: 46% of manufacturers are still managing production with tools that belong in a museum. That means wasted hours, missed deadlines, and compliance nightmares.

Think about it: manually updating spreadsheets for production schedules, digging through emails for certificates, or recalculating scrap rates after the fact. It’s slow, error-prone, and costing you money. Worse, it leaves your team firefighting instead of fixing the real problems.

Here’s the fix: modern AI tools that handle the boring, repetitive work for you. Imagine software that can instantly process mill certificates, optimise cutting patterns to reduce scrap, and adjust schedules in real time when things go wrong. That’s exactly what GoSmarter delivers.

The Old Way vs. The Smart Way

If your factory is still stuck in 1985, it’s time to change. Let’s look at how AI can save you time, money, and headaches.

Impact of AI on Automation, Fabrication and Manufacturing

What Production Managers Face in 2026

The gap between what your factory could achieve and what it actually delivers is growing wider. Sticking with outdated tools leads to higher costs, mounting stress, and shrinking profit margins. These issues, rooted in manual processes and ageing systems, create immediate challenges on the factory floor.

High Scrap Rates, Wasted Materials, and Missed Deadlines

Relying on outdated data to calculate scrap rates keeps your operations constantly behind. Manual calculations and schedule adjustments slow you down, with global manufacturing waste reaching a staggering 20% per pound - costing around £6.4 trillion annually [4]. A single rush order or unexpected machine breakdown can result in hours spent reworking a customised spreadsheet [1].

Compliance Problems with Manual Audits

When auditors request heat codes or mill certificates, scattered records buried in filing cabinets or email threads leave you scrambling. This reliance on outdated systems from the ’70s and ’80s, described as “rife with tech-debt”, forces teams to depend on manual data entry and institutional knowledge rather than real-time analytics [6]. If compliance hinges on remembering where certificates were filed months ago, you’re always one audit away from a crisis [3].

The Environmental and Financial Cost of Inefficiency

Inefficiency doesn’t just hurt your bottom line - it also derails sustainability efforts. Meeting modern “Green Steel” standards requires transparent, tamper-proof emissions data, something spreadsheets and manual logs simply can’t deliver [7]. Without real-time energy tracking, monthly bills offer little insight into which processes are guzzling kilowatt-hours or generating excess carbon [7].

Tony Woods, CEO of Midland Steel, explains: “Smart technology choices can have a direct, measurable impact on reducing carbon emissions in steel manufacturing. The integration of AI and digital tracking has significantly improved our operational efficiency and sustainability performance” [3].

While some companies have embraced real-time carbon tracking, sticking with guesswork risks your money and credibility. These inefficiencies highlight the need for AI-powered toolkits for smart manufacturing capable of transforming the way factories operate.

How GoSmarter’s AI Tools Modernise Your Factory

Modern factories face complex challenges, and GoSmarter steps in with tools designed to simplify and streamline operations. Unlike bulky enterprise systems that demand months of setup, GoSmarter integrates seamlessly with your current infrastructure. No need to rip out legacy systems or endure endless approvals - just log in, and you’re ready to go. Its three key AI tools tackle the manual tasks that bog down production, delivering a faster, more efficient workflow.

MillCert Reader: Say Goodbye to Manual Data Entry

Tired of typing out product codes from PDF certificates? GoSmarter’s AI-powered OCR handles it for you. In seconds, it extracts critical details like chemical composition, mechanical properties, and heat numbers. It even renames and organises documents by material grade, supplier, and batch number, turning bulk files into single-page PDFs sorted by heat code. This ensures every customer order has the right documentation.

But it doesn’t stop there. Automated validation rules cross-check material properties against industry standards like EN 10204 3.1, flagging any discrepancies early. Production managers save at least 10 hours a month [8], freeing up time to tackle real challenges instead of digging through endless email threads. The result? Improved compliance and a smoother workflow.

Smart Production Scheduler: Stay Ahead of Disruptions

Manual scheduling often feels like a juggling act, especially during rush orders or unexpected machine breakdowns. GoSmarter’s AI-driven scheduler takes the guesswork out of the equation. Using real-time data, it dynamically adjusts production runs, keeping everything on track. Unlike traditional methods that rely on static batch processing, this tool predicts bottlenecks before they occur, ensuring delivery dates are met without scrambling.

The benefits are clear: quicker turnaround times, fewer missed deadlines, and a production plan that adapts to your factory’s needs. It’s a smarter way to keep things running smoothly while maintaining efficiency.

Rebar & Scrap Optimiser: Cut Costs, Not Corners

Calculating cut lists manually often leads to errors and wasted materials. GoSmarter changes the game by running advanced mathematical models on your orders and stock, generating optimised cutting patterns in just five minutes [5]. It tracks offcuts and scrap, giving you a clear picture of material usage and helping you save for future needs.

In 2025, Midland Steel saw a 50% reduction in scrap rates after implementing GoSmarter’s AI planner for rebar operations [5].

Tony Woods, CEO of Midland Steel, said: “Smart technology choices can have a direct, measurable impact on reducing carbon emissions in steel manufacturing. The integration of AI and digital tracking has significantly improved our operational efficiency and sustainability performance.” [3]

GoSmarter also includes a Steel Emissions Calculator that estimates carbon output based on material, weight, and process choices. This tool supports detailed emissions reporting, helping you stay on top of sustainability goals [5]. Together, these tools deliver measurable improvements in cost savings and environmental impact.

How to Implement GoSmarter and Get Results Quickly

Log In and Start Immediately - No IT Headaches

Say goodbye to long-winded setups and endless approval processes. GoSmarter is designed for a hassle-free start - just log in, upload your Excel or CSV files, and you’re ready to go [3][5]. No need for a complex ERP overhaul. Instead, the platform works with your existing systems, upgrading them into smarter tools without the hefty price tag. Simply define your steel grades, product types, and stock locations once, then activate the features you need.

As Tadhg Hurley, Managing Director at MAAS Precision Engineering, aptly said:

“Choosing the right digital tools is no different like precision tools. We’re constantly seeking ways to improve our systems and processes with technology” [3].

His team quickly transitioned away from manual data entry, unlocking operational improvements almost immediately. This straightforward setup ensures you see measurable progress right from the start.

Measurable Results: Boost Margins and Reduce Waste

Once you’re set up, the platform delivers tangible savings. Start with the free scrap and emissions calculators to standardise your reporting [5]. Once you’ve established a baseline, you can tackle your biggest challenges with advanced tools. Extract data from mill certificates instantly, or upload your inventory and orders to generate optimised cutting lists with just one click [5].

Within weeks, you can expect results like:

• Teams saving over 10 hours monthly
• Scrap rates dropping by up to 50%
• Improved margins and fewer missed deadlines
• Better compliance records

The combination of time savings and operational efficiency means faster returns on your investment.

Flexible Plans for Every Operation

GoSmarter uses a “start for free, pay when you scale” approach [3]. Whether you’re operating a single facility or managing multiple sites, there’s a plan tailored to your needs. Here’s a quick breakdown to help you choose:

Pick a plan that tackles your most pressing challenges and scale up as your operation grows.

Conclusion

What Happens If You Do Nothing

Here’s the harsh reality: one small manual error can snowball into flawed production plans, inaccurate inventory counts, and shrinking profit margins [1][2]. Spreadsheets, no matter how detailed, quickly become outdated, forcing you to constantly firefight instead of staying ahead [1][2]. Even worse, critical operational knowledge often ends up locked inside the heads of a handful of employees who know how to navigate those intricate spreadsheets. This creates a bottleneck that stifles growth and leads to chaos as you try to scale [1].

Clinging to outdated systems keeps inefficiencies alive and opens the door to regulatory trouble. Imagine still chasing down mill certificates or manually crunching scrap rates when auditors demand instant, digital traceability. The result? Lost revenue, missed deadlines, and compliance headaches. These aren’t far-off risks - they’re inevitable outcomes when you try to run a modern factory with tools stuck in the past.

The Future Is Smarter, Faster, and Greener

The metals industry is evolving, with AI leading the charge toward autonomous processes, digital twins, and cleaner steel production [9][11]. And with AI data centres driving demand for higher precision and quicker turnarounds, the pressure to modernise is only growing [10].

As GoSmarter AI puts it:

“You didn’t hire your best people to copy-paste data from PDFs. Let automation handle the grunt work.” [3]

GoSmarter steps in to replace spreadsheet chaos with streamlined automation. It optimises cutting plans, simplifies compliance, and eliminates tedious admin - all without dragging you through a lengthy setup process. Just log in, upload your files, and start seeing real results in weeks.

It’s time to cut waste, lighten your admin load, and bring your factory into the future. Why wait?

FAQs