Overview

The "Balance Machines on Lines" page in the Garment IO AI Tool is designed to optimize line balancing by considering different machine types and process dependencies. This feature ensures an efficient distribution of work across machines, preventing bottlenecks and minimizing wasted capacity.

How to Use the "Balance Machines on Lines" Feature

Step 1: Select Order and Settings

1. Active Orders Only – Choose whether to filter for active orders or include all orders.
2. Select Order Number – Pick the order you want to balance.
3. Set Targeted Throughput per Hour – Define the expected production rate per hour.
4. Maximum Processes per Station – Set the limit on how many different processes can be assigned to the same machine.
5. Tolerance Level – Define the acceptable capacity variation:
   • If the threshold is 1 minute and the tolerance is 15%, any machine assigned 1.1 minutes of work will still be considered balanced.
   • If a station exceeds 1.15 minutes, the system splits processes across multiple machines to maintain balance and avoid bottlenecks.
   • Users can adjust the tolerance level as needed.
6. Select Time Format – Choose between:
   • Minutes
   • Minutes & Seconds
   • CMS (Cycle Measurement Standard)
   • Target per Hour

Step 2: AI-Driven Balancing & Calculation

Once settings are confirmed, the AI model performs calculations and displays:

• Order Stages – Shows different stages within the selected order.
• Total Number of Stations Required – The number of workstations needed.
• Total Number of Machines Needed – This may differ from the total stations if some stations require multiple machines working in parallel for balance.
• Wasted Capacity Percentage – Example: "7.0 - 24%" means that 7 machines are not fully utilized, leading to 24% wasted capacity.
  • The AI tool minimizes wasted capacity as much as possible.

Step 3: Reviewing the Table Data

The system generates a table containing critical details for each station:

Step 4: Analyzing the Dependency Graph

• Color Coding – Different machine types are visually distinguished by color.
• Graph Box Content – Each box represents a station and contains:
  • Station Number
  • Processes Assigned
  • Number of Machines
  • Utilization Percentage
• Underutilized Stations (Highlighted in Red) – If a station’s utilization falls below 50%, the system highlights its border in red.
  • This indicates excessive idle time for employees working at that station.
  • The system suggests employee rotation across multiple low-utilization stations to reduce waste.

This dependency analysis is repeated for each stage, allowing users to pinpoint inefficiencies and adjust balancing strategies accordingly.

Step 5: Reviewing the Summary Tables

At the bottom of the page, two summary tables provide an overview of the balancing results:

1. Overall Summary Table – Displays:

   • Total Stations Needed
   • Total Machines Required
   • Total Wasted Capacity

2. Machine Type Breakdown Table – Lists the number of machines required per machine type, helping ensure proper machine allocation.

Why Use "Balance Machines on Lines"?

✔ Optimized Line Balancing – Ensures a well-balanced workload across all machines and stations.
✔ Prevents Bottlenecks – Avoids excessive workloads on any single machine or workstation.
✔ Minimizes Wasted Capacity – Reduces machine and labor idle time.
✔ Flexible Adjustments – Users can modify tolerance levels, process limits, and time formats for better customization.
✔ Data-Driven Decisions – Visual graphs and structured tables provide clear insights for process improvement.

🚀 This feature is now available – start optimizing your production lines today!

For any questions or support, our team is ready to assist you!