The two views
DG verified preserves the original, shop-tested baseline behavior. Batch-aware models how quantities are distributed across heads and how operator handling can overlap with machine operation. Both are displayed so a shop can compare the familiar baseline with the more detailed model.
Machine time
For each location, stitch time is based on stitches, effective RPM, quantity, and the number of machine heads. Effective RPM includes the machine-efficiency setting and the optional design-speed factor. Color changes, trims, manual stops, expected thread-break time, and estimated bobbin changes add predictable machine occupancy.
Operator time
Setup includes loading the design and entering machine settings. Handling includes marking, hooping, removing the hoop, finishing, and packing. Garment type and the per-location handling factor affect the result. Batch-aware mode lets a configurable share of operator work overlap with machine time.
Default calibration
The included profile uses measured starting values including 120 seconds to load a design, 110 seconds for settings, 15 seconds per placement to mark, 25 seconds to hoop a shirt placement, 40 seconds to hoop a hat placement, 15 seconds to remove a hoop, 22 seconds to fold or steam, and 10 seconds to pack. Machine efficiency starts at 85%, expected downtime at 15 seconds per 1,000 stitches, and contingency at 33%.
Those numbers are not standards. Machine model, operator experience, fixture choice, design quality, garment structure, thread, backing, and work-cell layout can move them substantially. Use the calibration panel to represent your process.
Contingency
The contingency percentage is added after the modeled production components. It is intended for ordinary variation—not major breakdowns, rush interruptions, approval delays, material shortages, or rework.
DST parsing
The analyzer reads Tajima stitch commands locally. Stitch count, movement, extents, jumps, and color-change commands come from the command stream. DST does not reliably carry thread names and does not provide a universal explicit trim instruction, so trims are inferred from jump patterns and labeled accordingly.
Image and thread color matching
Image samples are represented in sRGB, converted to Lab, and ranked against electronic-card values with the CIEDE2000 color-difference formula. Approximate PMS references use community screen values and are not official Pantone data. A physical thread card and sew-out remain the final authority.
What the result is not
The estimate is not a quote, warranty, service-level commitment, or substitute for operator judgment. Use actual-finish comparisons and known shop constraints before committing to a deadline.