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Cortrova is a fully built, AI-enabled manufacturing ERP platform designed for small-to-mid-size manufacturers with 10 to 500 employees. It unifies 17 operational domains — Safety, Quality, Delivery, Inventory, Finance, HR, Production, Maintenance, Engineering, Sales, Procurement, Regulatory, Environmental, Facilities, IT/OT, Customer Service, and R&D — into a single platform powered by Trunnion AI. Cortrova includes 205+ features and 33 cross-module integrations, all available from day one with no phased rollout required.

The 17 domains are: Safety (EHS, 47 features), Quality (QMS, 31 features), Production (OEE, work orders, downtime), Maintenance (CMMS, predictive maintenance), Inventory (SKU management, cycle counts), Delivery (OTD, shipment tracking), Finance (GL, AP/AR, CapEx — 31 features), Procurement (PO, RFQ, supplier scorecards), Engineering (ECO, BOM, NPI), Sales (CRM, pipeline, forecasting), HR (recruiting, scheduling, performance), IT/OT (help desk, ITSM, security), Regulatory (submissions, compliance calendar, AI mock auditor), Customer Service (cases, field service, warranty), Environmental (emissions, ESG, carbon), Facilities (building systems, capital projects), and R&D (projects, innovation pipeline, IP records). All are connected through 33 cross-module integrations.

The 5 core ERP modules — Safety, Quality, Delivery, Inventory, and Finance — form the primary manufacturing operational pillars with traffic-light KPI monitoring. The full platform extends to 17 operational domains by adding Production, Maintenance, Procurement, Engineering, Sales, HR, IT/OT, Regulatory, Customer Service, Environmental, Facilities, and R&D. All 17 domains are fully integrated and monitored by Trunnion AI. The 5-pillar traffic-light dashboard aggregates core manufacturing health, while the full 17-domain view provides complete operational visibility.

Frontend: React 19 + TypeScript, Material-UI 7, Tailwind CSS, Vite 7, Socket.io, Three.js, Recharts, Framer Motion. Backend: NestJS 11 + TypeScript, Prisma ORM 7, PostgreSQL, Socket.io, optional Redis. AI: Anthropic Claude API + OpenAI API with custom statistical ML engines. Deployment: Docker, Nginx reverse proxy. The platform includes ~1,286 API endpoints across 60 NestJS modules, 100+ Prisma database models, 400+ frontend page components, and 147 AI-specific TypeScript files.

Cortrova supports 12 distinct user roles with role-based dashboards and role-adaptive AI briefings. Executive: CEO/COO, CFO, VP Operations, VP Quality, VP EHS. Management: Plant Manager, Department Managers, Supervisors. Operational: Floor Operators, Quality Inspectors, Maintenance Technicians, Safety Coordinators, Procurement Specialists, IT Administrators. Every role receives a daily AI briefing tailored to their specific operational context and KPI set.

Yes. Cortrova includes full mobile and offline capability. The Voice Companion feature allows field workers to speak commands and observations hands-free — audio is transcribed, intent parsed, and actions executed (create incident report, log observation, check work order status) with automatic geolocation capture. Offline mode allows continued operation without connectivity and auto-syncs on reconnection. This is designed for floor workers wearing PPE who can't type on tablets.

Yes. Cortrova's standard lease includes up to 3 facilities. Additional facilities are available as an integration add-on. The Cross-Site Analyzer compares safety, environmental, and operational KPIs across all facilities — surfacing underperforming sites before a miss becomes an incident. The unlimited-user pricing model means every employee at every facility is covered under one flat annual fee.

Trunnion AI is the artificial intelligence engine powering Cortrova. It operates as a 64-agent, three-tier intelligence hierarchy monitoring all 17 operational departments simultaneously. Unlike bolt-on analytics tools, Trunnion AI is embedded directly into every module, every dashboard, and every workflow. It supports both Anthropic Claude and OpenAI GPT via a provider abstraction layer, allowing different departments to use different models based on task requirements and cost optimization.

Tier 1 — Department Agents (51 agents): Each of 17 departments has an Analyst (detects anomalies, ~8,000 token context), an Advisor (generates recommendations for specific records, ~4,000 token context), and a Reporter (generates summaries every 30 minutes, ~6,000 token context).

Tier 2 — Division Aggregators (7 aggregators): Synthesize insights across related departments every 30 minutes using ~10,000 token contexts. Divisions: Operations & Production, Safety/Regulatory/Environmental, Finance & Procurement, Supply Chain & Logistics, People & Facilities, Commercial & Customer, Technology & Innovation.

Tier 3 — Executive Agents (6 specialists): Strategy, Operations, People & Culture, Risk & Compliance, Market Intelligence, plus a Synthesizer producing a unified C-suite briefing using 12,000–16,000 token contexts.

The Predictive Incident Convergence Engine runs 8 parallel Factor Collectors: ExpiredTrainingCollector, OverdueMaintenanceCollector, OvertimeFatigueCollector, NearMissClusterCollector, OpenHazardCollector, OverdueCAPACollector, FailedInspectionCollector, and EquipmentAgeCollector. Locations with 3+ simultaneous factors receive a compound severity score, incident probability elevation, and predicted timeframe (7–30 days).

Example: "Building C, Shift 2 has 5 converging factors → 65% incident probability vs 8% baseline within 14 days."

No other platform combines 8 risk factor collectors across 4 different departments (Safety, Maintenance, Quality, HR) into a single convergence score with predicted timeframe.

Trunnion AI maintains a graph of 50+ pre-seeded causal relationships between metrics across all 17 domains, each with impact coefficients, confidence scores, and lag periods. This enables what-if scenario modeling — for example: "If TRIR increases by 0.5 → Quality FPY will decrease by 15% (confidence: 0.75, lag: 2 periods) → Material cost variance increases by 9% (confidence: 0.90, lag: 1 period) → Cash conversion cycle extends by 3 days." Executives can see how a safety incident cascades through quality, finance, and delivery — with dollar amounts attached.

The AI Mock Compliance Auditor creates interactive audit sessions where a rigorous AI inspector persona asks probing questions about compliance against any regulatory framework — ISO 9001, ISO 14001, FDA 21 CFR, IATF 16949, OSHA PSM, CMMC, DFARS, and more. Findings are classified as OBSERVATION, MINOR NON-CONFORMITY, or MAJOR NON-CONFORMITY. Companies typically spend $50,000–$200,000 on third-party audit preparation. This lets any team run a realistic mock audit at any time, with an AI that asks the same hard questions a real auditor would.

The Predictive Alert Engine runs three statistical methods every 6 hours on every tracked metric: Linear Regression Trend Analysis (least-squares regression with forward projection, R² > 0.3 required), Moving Average Deviation (7-period vs 30-period SMA comparison, Z-score anomaly detection at ±1.5σ), and Threshold Proximity Analysis (alerts when metrics are within 10% of red thresholds). Alerts include severity levels (CRITICAL, HIGH, MEDIUM, LOW) and confidence scores. Data quality assessment applies confidence multipliers from 1.0x (HIGH quality) down to 0.2x (INSUFFICIENT data).

The Narrator is a full multi-turn conversational AI with live context from all 17 operational domains. Users ask natural language questions — "Why did our scrap rate spike last week?" — and receive answers grounded in actual operational data with cited sources. Each query loads the last 20 conversation messages, queries all 17 domains for current metrics and open issues, and calls Claude Sonnet or GPT-4 at temperature 0.4 with up to 2,048 token responses. Responses are cached for 5 minutes and rate-limited per user. This is not generic AI — it knows your specific TRIR, open CAPAs, cash position, and overdue PMs.

Every AI request passes through: Team Guard → Kill Switches → Rate Limiting → Budget Check → Scope Validation → LLM Call → Audit Log. Kill switches operate at three levels: Global (disables all agents), Division (disables all teams in a division), and Team (disables one department). The Scope Registry defines which database models each AI team can access — Safety agents cannot access Finance models. Rate limiting: 60 RPM per user/team via Redis. Token budgets: daily per-team with 80% warning and 100% hard stop. Every agent action is immutably logged with team ID, agent type, domain, tokens used, and response time.

SAP S/4HANA costs $200+ per user per month with $75,000–$500,000+ implementation and 6–18 month deployment. Cortrova uses flat-rate unlimited-user annual pricing with $15,000–$50,000 integration cost and 4–8 week deployment. SAP's Joule AI is limited and separate; Cortrova's Trunnion AI is natively embedded across all 17 modules. SAP's Safety/EHS module is a separate product purchase; Cortrova includes 47 EHS features natively. For a 50-person manufacturer at $30M revenue, SAP's 5-year TCO is $1,500,000–$2,500,000+; Cortrova's is $900,000–$1,000,000 including integration.

Plex costs $3,000+/month (~$500/user) with $100,000–$200,000+ implementation and 3–6 month deployment. Cortrova uses unlimited-user flat-rate annual pricing with $15,000–$50,000 integration and 4–8 week deployment. Plex has no native AI intelligence; Cortrova includes Trunnion AI with 64 agents. Plex has a partial Safety/EHS module; Cortrova includes 47 dedicated EHS features. 5-year TCO for a 50-person manufacturer: Plex $1,600,000+, Cortrova $900,000–$1,000,000.

Epicor Kinetic costs $125–$175/user/month with $75,000–$500,000+ implementation and 4–12 month deployment. Cortrova uses unlimited-user flat-rate pricing with $15,000–$50,000 integration and 4–8 week deployment. Epicor has no native AI; Cortrova includes Trunnion AI natively. Epicor has no Safety/EHS module; Cortrova includes 47 features. Epicor requires phased module rollout; Cortrova delivers all 205+ features on day one. 5-year TCO: Epicor $1,000,000–$1,500,000+, Cortrova $900,000–$1,000,000.

Cortrova is purpose-built for manufacturers with 10–500 employees. Its key advantages for this segment: Flat-rate unlimited-user pricing eliminates the per-seat cost anxiety that prevents SMMs from giving every employee access. 4–8 week deployment vs 4–18 months for enterprise alternatives. Full platform on day one — no phased rollouts. Native AI intelligence (Trunnion AI) included, not an add-on. 47-feature EHS module — the most comprehensive of any mid-market ERP. At $30M in annual revenue, Cortrova represents under 1% of revenue — well below the 1–3% industry average ERP spend.

Cortrova's Safety module includes 47 features: incident reporting with autonomous AI investigation (INJURY, NEAR_MISS, PROPERTY_DAMAGE, ENVIRONMENTAL, FIRE, CHEMICAL_SPILL), hazard management with probability × severity risk matrix, audit management with finding-to-closure tracking, training and certification management with expiry alerts, permit-to-work system (hot work, confined space, elevated work), compliance calendar with automated regulatory reminders, risk register, safety bulletins and toolbox talks, behavioral-based safety observation tracking, SOP lifecycle management, and the Predictive Incident Convergence Engine. KPIs tracked: TRIR, DART Rate, Lost Time Injury Rate, Near-Miss Ratio, Audit Compliance %, Training Compliance %, Open Hazards, Permit Compliance.

Cortrova's Quality module includes 31 features: incoming, in-process, and final inspection workflows; defect tracking with root cause categorization and containment; CAPA management (identification through effectiveness verification); NCR disposition (USE_AS_IS, REWORK, REPAIR, SCRAP, RETURN_TO_SUPPLIER); customer complaint management; supplier quality scoring with SCAR issuance and audit scheduling; calibration scheduling and tracking; SPC with automated Cpk/Cp calculation and 3σ out-of-control detection; quality audits (internal, supplier, customer, ISO); document control (SOPs, work instructions, FMEA, PPAP); and an AI root cause suggestion engine matching cases against 200+ historical closed CAPAs. KPIs: First-Pass Yield, DPMO, Scrap Rate, Rework Rate, Supplier Quality Average, CAPA Closure Rate, Cost of Quality.

Cortrova's Finance module includes 31 features across 27 pages: General Ledger with journal entry approval workflow (DRAFT → APPROVED → POSTED → REVERSED), Accounts Payable with 3-way matching (PO/Receipt/Invoice), Accounts Receivable with aging analysis and collections, Expense Management with approval workflow, Cost Centers with departmental allocation and variance, Period Close with task assignment and period lock, Bank Reconciliation, CapEx tracking from proposal through ROI analysis, Fixed Assets with depreciation (straight-line, declining balance, double-declining, units of production), Budget planning and variance analysis, Cash Flow forecasting. AI features: budget variance prediction, labor efficiency trending, material cost variance analysis, cash conversion cycle monitoring, working capital optimization.

Cortrova's Maintenance module covers: work order lifecycle (Request → Approve → Plan → Schedule → Execute → Close), asset registration with criticality classification (CRITICAL/HIGH/MEDIUM/LOW), preventive maintenance scheduling (time, meter, or condition triggers), predictive maintenance with sensor data (vibration, thermal, oil analysis, ultrasonic), spare parts inventory and reorder alerts, downtime tracking with cost calculation, failure analysis (RCFA), and MTBF/MTTR trending. AI features: OEE prediction and degradation forecasting, downtime pattern anomaly detection, overdue maintenance risk factor feeding into convergence zones, equipment age failure probability modeling. The difference from standalone CMMS: maintenance data connects automatically to Safety risk scores, Inventory spare parts, Production OEE, and Finance cost tracking.

Cortrova's HR module (22 pages, 14 backend routes) covers: Employee Management (master profiles, status tracking), Recruiting/ATS (requisitions, applications, interviews, offers), Onboarding (task checklists, orientation scheduling), Leave Management (VACATION, SICK, PERSONAL, BEREAVEMENT, FMLA with accrual tracking), Compensation (salary management, raise tracking), Performance Reviews (cycles, ratings, improvement plans, discipline), Training (courses, enrollment, certification management), Skills Matrix (proficiency assessment, gap analysis), and Scheduling (FIRST, SECOND, THIRD, ROTATING, FLEXIBLE shifts). AI: turnover rate prediction, absenteeism pattern detection, overtime fatigue analysis, workforce risk scoring (AI-powered employee incident propensity modeling).

Cortrova's Supplier Risk Scoring Algorithm produces a real-time multi-factor score (0–100) combining: quality score degradation (0.5x per point below target), open SCARs (10 pts each, capped at 30), recent NCRs (8 pts each, capped at 25), overdue audit impact (5 pts per 10 days, capped at 20), probation status (15 pts), conditional status (8 pts), and delivery score gaps. Scores are calculated continuously and trigger automatic escalation at risk thresholds. Supplier quality issues cause 40% of manufacturing recalls — this algorithm provides quantified advance warning before a crisis hits production.

Cortrova's SPC engine automatically calculates Cpk and Cp process capability indices for all active measurements, detects process drift using a 1σ threshold comparison between the first and second halves of data, and flags out-of-control points beyond 3σ. The engine runs continuously — most quality teams review control charts weekly and react after bad parts ship. Cortrova's engine alerts before shipment. Out-of-control events automatically trigger CAPA workflow creation, linking the SPC alert directly to corrective action without manual intervention.

Cortrova's Environmental module covers: emissions tracking by source with permit limit comparison, waste categorization and disposal tracking with manifest management, carbon and GHG emissions calculation, energy consumption and utility tracking by facility, water usage monitoring, LCA support, and ESG reporting with data quality monitoring. AI: emissions threshold breach prediction, waste generation pattern detection, energy consumption anomaly detection, carbon footprint forecasting tied to production volume, environmental permit compliance risk scoring. KPIs: Total Emissions (CO2e), Emissions vs Permit Limits, Waste Diversion Rate, Energy Intensity, Water Usage per Unit, Carbon Footprint Trend, Permit Compliance %, ESG Score.

Cortrova serves: Aerospace & Defense (AS9100, NADCAP, ITAR/EAR, PPAP/FAI), Automotive (IATF 16949, OEE, PPAP, JIT delivery), Industrial Manufacturing (general ERP/CMMS/EHS), Energy & Utilities (EPA, OSHA PSM, ESG reporting, asset-intensive maintenance), Food & Beverage (FDA 21 CFR, FSMA, HACCP, lot traceability), Defense (CMMC, DFARS, CUI controls), and Government manufacturing facilities (FAR, FISMA, multi-agency compliance, appropriations budgeting).

Cortrova supports compliance management for: Quality: ISO 9001, IATF 16949, AS9100 Rev D. Environmental: ISO 14001, EPA regulations. Food Safety: FDA 21 CFR, FSMA, HACCP. Safety: OSHA General Industry, OSHA PSM. Defense: CMMC Levels 2 & 3, DFARS, ITAR/EAR, CUI controls, DCSA. Energy: NERC. Government: FAR, FISMA. The AI Mock Compliance Auditor supports interactive audit preparation for any of these frameworks.

For aerospace manufacturers, Cortrova provides: AS9100/NADCAP compliance audit management with finding-to-closure tracking; ITAR/EAR export license management with access controls and audit trails; FAI and PPAP documentation workflows; full lot and serial traceability from raw material receipt through shipment; ECO configuration control with multi-level approval and impact analysis; calibration management for all measurement and test equipment; supplier risk scoring and SCAR management; and the AI Mock Auditor for AS9100 and DCSA readiness preparation. The Predictive Incident Convergence Engine is particularly valuable for high-risk aerospace production environments.

For food and beverage manufacturers, Cortrova provides: FDA 21 CFR and FSMA compliance management with audit tracking; HACCP plan management with critical control point monitoring; full lot and batch traceability from raw material receipt through finished goods shipment for one-up/one-down recall readiness; FIFO/FEFO inventory rotation enforcement with shelf-life management and quarantine holds; sanitation work order and inspection scheduling; supplier quality scoring and SCAR management for ingredient suppliers; and environmental compliance for water, wastewater, and waste generation against permit limits.

Cortrova is fully built — implementation is integration only, not a phased buildout. Typical timeline: Week 1: Discovery, data audit, integration planning, role/permission matrix. Weeks 2–3: Data migration (master data, BOMs, customers, suppliers, employees). Weeks 3–4: System configuration, workflow rules, Trunnion AI calibration. Weeks 4–6: Role-specific user training (executives → managers → supervisors → floor). Weeks 5–8: Parallel run, validation, and go-live with dedicated support. Ongoing: quarterly business reviews and AI model refinement. Total: 4–8 weeks versus SAP (6–18 months), Plex (3–6 months), Epicor (4–12 months).

Cortrova uses a flat-rate annual software lease with unlimited users and all 205+ features included from day one. No per-user fees. No monthly charges. No feature tiers. No module upsells. Minimum 2-year contract. Longer commitments receive meaningful discounts. The only additional costs are one-time integration fees: Standard integration: $15,000–$50,000 (single-facility, most manufacturers). Complex integration: $50,000–$100,000 (multi-system, legacy data conversion, IoT sensors, multiple facilities). Custom API development: $175/hour. Contact Cortrova at cortrova.com/contact for specific pricing.

Yes. Cortrova connects to existing ERP systems, MES, SCADA, IoT sensors, EDI networks, and other data environments during integration. Standard integrations cover data migration, system configuration, and role setup. Complex integrations handle multi-system bridges, legacy data conversion, IoT sensor configuration, and EDI mappings. Custom API integration development is available at $175/hour for specialized interfaces. The integration approach means no rip-and-replace — Cortrova layers on top of existing infrastructure where needed while providing the full unified platform from day one.

Standard support (included with every lease): phone, email, and in-app support during business hours; ongoing software updates and new feature releases; quarterly business reviews; and continued Trunnion AI model refinement. Premium Support upgrade: 24/7 phone support, 4-hour response SLA, and a dedicated Customer Success Manager. Training beyond the initial onboarding package is available at $2,500/day on-site. All customers receive API access for third-party integrations and access to all new features as they are released — there are no feature tiers or upsells after signing.