Spot issues before they become problems
The challenge
Traditional production management operates reactively—you discover problems after they've already reduced output, created bottlenecks, or impacted delivery schedules. By the time end-of-shift reports show underperformance, the productive hours are already lost. The constant cycle of problem discovery, investigation, and correction consumes resources that could go toward prevention.
Why it happens
Without real-time visibility into production dynamics, issues only become apparent through their downstream effects. A line imbalance shows up when output falls below target. Operator fatigue becomes visible when quality suffers. Machine performance degradation reveals itself through increased stoppage frequency—but only after that frequency has already affected production. The detection lag means you're always managing consequences rather than addressing causes.
Our solution
OpenSeam's Constraint Discovery System identifies developing issues as they emerge, not after they cascade into production impact. Line imbalances appear when station cycle times start diverging, before overall throughput declines. Operator stamina patterns show developing fatigue before it affects output quality. Machine behavior changes signal maintenance needs before breakdowns occur. The system reveals constraints in formation, enabling intervention before impact.
The outcome
Management attention shifts from crisis response to preventive action. When you see a constraint developing, you can rebalance the line before it creates a bottleneck. When stamina patterns indicate operator fatigue, you can rotate assignments before quality suffers. When machine behavior suggests impending issues, you can schedule preventive maintenance during planned downtime rather than emergency repairs during production. The production impact of problems decreases because you address them earlier in their lifecycle.
How we deliver
The Constraint Discovery System runs continuously in the background, analyzing production patterns across all stations. When it identifies developing constraints, Tally routes notifications to appropriate stakeholders with context about what's emerging and where. The Yamazumi chart interface shows constraint severity visually, helping you prioritize responses. You gain awareness of problems while they're still small and manageable rather than after they've grown into production crises.