To make sure batches are merged through the workstation and their merging stage is recorded, it is essential to complete the merge right from the workstation. This guide explains how to use the Merging action, from creating and configuring merge and grouping rules, through scanning and reviewing batches, to assigning the batch group card and confirming the merge.

Overview of Merging from Workstations

Batch merging used to be performed from stations. The merge operation was not part of the workstation process flow and did not produce a production operation for merging. Merging is now a dedicated action inside the workstation that takes part in the process flow and creates the corresponding merging stage when the operation succeeds.

A workstation can also manage multiple merge sessions at the same time, with grouping rules configured separately for each session, instead of relying on a single workflow tied to one station.

Prerequisites

• The user must have access to the batch grouping and merging function.
• A suitable merging operation must be assigned to the workstation before the Merging action is used.
• The batches being merged must belong to the same production order.
• At least two valid batches are required to complete the merge.

Before You Start

The batch merging workstation must be set up before workers can use it:

• Add a workstation or edit an existing one, and select the batch merging action for it. See the Workstations article to learn more about workstation types and workstations themselves.

Adding a Merging Workstation

• Create the mandatory standard operation under the style category, and set its type as a control operation.
• Link this batch merging operation to the batch merging workstation type, so the workstation type knows which operation it must verify.
• The standard time for the batch merging stage can be set to zero, provided this option is first enabled from the Garment IO Advanced Settings on the Factory Management page.

Creating a Standard Operation for the Merging Batches Stage

• On the style page, add the batch merging operation.

Adding the Merging Batches Operation

• The batch merging operation type accepts zero as a valid standard time. If your factory settings do not generally allow a standard time of zero, check with your system administrator, because this setting may affect whether a control operation with a zero standard time is accepted when it is saved.

Merging Workflow at the Workstation

• Open the workstation on which the merging operation has been configured.
• Choose the Merging action from the workstation actions. Access to this action is controlled by the batch grouping permission.
  

• Create new merge rules. A workstation can have multiple merge sessions, which lets you prepare different groups of batches separately.
• Select the batch group type and, optionally, lock the attributes that must match between batches.
  

• Scan the batches to include in the merge. The first scanned batch sets the reference values for any locked rules.
  

• Review the selected batches: the production order, batch count, piece count, and selected grouping rules, before confirming the merge.
  

• Select "Merge into Batch Group". The system validates the selected batches before creating the merged batch group.
• After the group is created, scan the card for the new batch group. Cards can be added or removed before final confirmation.
  

• Confirm the merge after reviewing the group information and the scanned card.
• A successful merge is processed as a merging production action and creates the corresponding merging stage for the batches involved.

Configuring Merge Rules

When starting merge rules, the user selects a batch group type and can define which batch attributes must match. These rules are applied to every batch scanned afterward.

• Cutting order: all batches must have the same cutting order as the first scanned batch.
• Size: all batches must have the same size as the first scanned batch.
• Color: all batches must have the same color as the first scanned batch.
• Color shade: the color shade information must be compatible with the first scanned batch.
  

A rule does not need to be locked. When a rule is not locked, the corresponding attribute may differ between the batches in the merge session.

Batch Validation

The system validates each scanned batch before adding it to the current merge session. A batch is rejected when it does not satisfy the merge requirements:

• The same batch cannot be scanned twice in the same merge session.
• Batches from different production orders cannot be combined.
• A batch that is already associated with the selected batch group type cannot be added to that group.
• Locked grouping rules must match the first scanned batch.
• The merge action remains unavailable until at least two batches are selected.

Reviewing and Confirming the Merge

Before the merge is finalized, the confirmation view summarizes the selected group. You can review the batch numbers, the total piece quantity, the group type, and any locked grouping rules.

You can go back from the confirmation step if changes are required, and the batch group card can also be managed before final confirmation.

The Merging Stage

The main change in this feature is that workstation merging is now linked to its recording as a production operation. The merging operation assigned to the workstation is used when the merge is evaluated.

• The merging operation must be assigned to the workstation before the operation is performed.
• The system validates the merge before the operation is completed.
• When the merge succeeds, the system creates a production operation for the batches involved.
• If the selected batches are not eligible for the merging operation, the merge is not completed and no merging stage is created.

Multiple Merge Sessions

A workstation can maintain multiple merge sessions. Each session can have its own batch group type, grouping rules, and scanned batches. Users can switch between sessions and continue preparing each group independently.

This lets operators prepare different groups without mixing their selected batches or grouping requirements.

Permissions and Access

The Merging action is protected by the batch grouping access permission. Users without this permission cannot enter the merging workflow from the workstation.

Expected Result

After a successful operation, the selected batches are combined into the requested batch group, the batch group card can be assigned, and the workstation merge is recorded through the corresponding merging stage.

Error Scenarios You May See

• Duplicate batch scanned: the batch is rejected and is not added to the merge session.
• Batch belongs to another production order: the batch is rejected.
• Batch violates a locked rule: the batch is rejected and the user is told which grouping requirement was not satisfied.
• Invalid batch group type for a batch: the batch is rejected.
• Only one batch selected: the merge action remains disabled.
• User lacks merging access: the workstation prevents entry into the Merging action.
• Merge operation is not eligible: the merge is not completed and no merging production operation is created for the rejected operation.

Frequently Asked Questions (FAQs):

• What must be set up before using merging at the workstation?
  A suitable merging operation must be assigned to the workstation, and the user must have the batch grouping permission.

• How many batches do I need to complete a merge?
  At least two valid batches. The merge action stays disabled while only one batch is selected.

• Can I merge batches from different production orders?
  No. All batches must belong to the same production order, and a batch from another order is rejected.

• What does locking a grouping rule mean?
  When you lock a rule such as cutting order, size, color, or color shade, every batch scanned afterward must match the first scanned batch on that attribute. If the rule is not locked, the attribute may differ between batches.

• Can I work on more than one group at the same time?
  Yes. A workstation can keep multiple merge sessions, each with its own group type, rules, and scanned batches.

• When is the merging stage created?
  When the merge succeeds from the workstation. If the batches are not eligible for the merging operation, the merge is not completed and no production operation is created.

• Can I go back after reaching the confirmation step?
  Yes. You can go back from the confirmation step if changes are required, and you can add or remove the batch group card before final confirmation.

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