Meet Tally,
Intelligence at work
OpenSeam's AI production assistant is called Tally. It continuously monitors your factory floor, discovers constraints as they emerge, and routes actionable tasks to the right stakeholders at the right time.
Built specifically for garment manufacturing, Tally understands production dynamics and ensures critical issues get attention before they cascade into larger problems.
How Tally changes production
From reactive to intelligent
Traditional methods:
- Issues discovered after they impact output
- Supervisors firefighting all shift
- Constraints identified only through effects
- Management only has delayed information
With Tally:
- Constraints discovered as they form
- Stakeholders notified before impact cascades
- Interventions can be targeted at root causes
- Management acts on real-time intelligence
From poor flagging to smart flagging
Traditional methods:
- Everyone gets notified about everything, or
- Nobody gets notified about anything, or
- Manual coordination determines who should know
With Tally:
- Floor supervisors receive alerts for their assigned lines
- Mechanics get machine-specific notifications
- Engineers see pattern-based strategic insights
Each stakeholder receives relevant, actionable information
What Tally does
Monitor production, non-stop.
Tally analyzes real-time data from each seambit sensor, at each sewing station, across your production floor. It tracks performance patterns, identifies developing constraints, and monitors production health continuously—never missing a moment, never overlooking a station.
Discover constraints, as they form.
Using Theory of Constraints principles and garment manufacturing domain understanding, Tally identifies which stations are actually limiting line throughput, right now. Not guessing, not sampling—it discovers constraints through continuous analysis of:
- Pace variations
- Proficiency levels
- Stoppage patterns
- Stamina indicators
- Machine runtime
Assign tasks and route flags.
When Tally discovers a constraint or detects an issue requiring attention, it doesn't just log it—it acts:
- Identifies the issue - What's happening and where.
- Determines stakeholder - Who should address this.
- Creates the task - Specific action needed with relevant context.
- Sends notification - Right persons gets alerted, asap.
- Tracks response - Ensures issues don't slip through.
The intelligence behind Tally
Theory of constraints application
Tally applies established production optimization principles automatically:
- Identifies system constraints - Which station limits overall throughput
- Focuses attention - Routes resources to actual bottlenecks
- Enables strategic decisions - Shows where improvement efforts matter most
- Reveals constraint shifts - Tracks how bottlenecks move throughout the day
This isn't generic AI trying to learn your factory—it's manufacturing intelligence built specifically for garment production dynamics.
Context-aware notifications
Tally understands that the same data means different things to different roles:
- A pace drop might alert a floor supervisor to check the operator
- The same pace drop might alert a mechanic if it correlates with machine behavior
- If pace drops appear as a pattern across multiple stations, an industrial engineer sees it as a potential line balancing issue
The AI routes information based on what it means, not just what it measures.
What stakeholders experience
For floor supervisors
Tally becomes your eyes on stations you're not currently observing:
- Mobile notifications when stations on your lines need attention
- Specific context about what's happening and where
- Priority indicators so you address critical issues first
- Pattern alerts when multiple stations show related problems
You stop wandering the floor hoping to spot issues and start responding to intelligent alerts that route you efficiently.
For industrial engineers
Tally surfaces insights that manual observation simply can't capture:
- Constraint identification showing actual bottlenecks in real-time
- Pattern recognition across lines, shifts, and operations
- Historical comparison of constraint behavior over time
- Strategic alerts when systemic issues emerge beyond individual station problems
Your analysis starts with discovered constraints rather than guesswork about where problems might be.
For mechanics
Tally routes machine-specific issues directly to you:
- Diagnostic context about machine behavior patterns
- Historical performance showing degradation over time
- Preventive alerts when machines show early warning signs
- Priority routing for issues requiring immediate technical attention
You spend time fixing actual problems rather than investigating false alarms or discovering issues after breakdown.