TextileMode Capacity Engine
Context: Mid-market textile manufacturer operating 27 industrial looms with daily batch constraints.
“Daily scheduling and production routing across 27 industrial looms required 10 dispatch clerks running manual spreadsheets, managing PKR 3 crore ($107,000/mo) in monthly throughput with persistent delivery backlogs.”
Real-world boundaries
What was deployed
Engineered an automated capacity-matching system calculating loom throughput, yarn lots, and lead times with strict constraint satisfaction and continuous production oversight.
Verified results
“We replaced a room of 10 dispatch clerks with 1 review operator. All 27 looms run on predictable batches with zero scheduling backlogs.”
The friction encountered
Friction: Initial algorithm did not account for 15-minute loom warm-up cycles, which caused minor shift-start discrepancies in week one.
Remediation: Added calibration offsets for mechanical warm-up into the dispatch schema.
What I'd do differently
Would have conducted on-site line observation during shift changeovers earlier in discovery.
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