Continuous monitoring at impossible scale
The challenge
Comprehensive production monitoring would require an army of supervisors performing constant spot checks at every station throughout every shift. Even with significant management overhead, human observation can only sample production intermittently—a supervisor might check a station every 30 minutes, missing the 29 minutes and 30 seconds in between.
Why it happens
Human attention doesn't scale to factory requirements. A single supervisor might oversee 50-100 stations across a production line. Even dedicated observation of one station can't capture every moment—people blink, look away, handle interruptions, move between stations. The granularity needed to understand true production behavior simply exceeds human capability.
Our solution
OpenSeam's seambit sensors check station activity every 5 milliseconds. For a mid-sized factory with 1,000 active sewing stations, this means 7.2 billion measurements every single shift. Every needle movement, every pause, every burst of activity gets captured with millisecond precision. The system never blinks, never looks away, never misses a moment.
The outcome
You gain observational granularity that was never possible before. Patterns invisible to periodic human checks become clear—micro-stoppages that happen between supervisor rounds, pace variations across the shift, fatigue onset in specific time windows. The data density enables analysis that couldn't exist with sampled observations. Issues hiding in the gaps between manual checks now appear in continuous measurement.
How we deliver
This monitoring scale happens automatically the moment seambits are installed. There's no configuration for sampling rates or observation schedules—continuous measurement is simply how the system works. The 7.2 billion measurements per shift don't create 7.2 billion data points for you to review; our processing pipeline converts raw sensor data into meaningful metrics and alerts. You get the insight this measurement density enables without the cognitive burden of processing billions of individual observations.