Flagship queue simulator

Embroidery Order Mix & Queue Planner

Model several real jobs together instead of pretending every order has the same stitch count, product type and batch size. Compare modular single-head fleets with synchronized multi-head production.

Mixed jobsPartial-head mathOperator bottleneckBrowser only

Your queue

Enter up to six jobs

Job	Type	Qty	Stitches / pc	Same-design batch

Production window

Production days available

Machine hours / day

Reserved capacity buffer (%)Capacity intentionally kept free for rush work and variability.

Setup / changeover per job (min)

Measured shop assumptions

Flat minutes / 1,000 stitches

Cap minutes / 1,000 stitches

Flat hoop/load min / piece

Cap hoop/load min / piece

Operators feeding machines

Rework / reject allowance (%)

Queue verdict

—

Total good pieces—

Smallest fit—

Head loading—

Operator pressure—

Architecture	Queue hrs	Head use	Operator	Window

This is a capacity model, not a promise date. Artwork, approvals, blank inventory, maintenance and shipping are outside the queue.

Why this is different

A shop is a queue, not an average order.

Mixed batches

A 6-head is excellent for 72 matching polos and awkward for one-off personalization. The queue keeps those jobs separate.

Caps stay separate

Caps can have different real run and handling time, so they are not blended into one optimistic SPM assumption.

Architecture matters

Independent heads can run unrelated jobs simultaneously. Traditional synchronized heads multiply identical pieces per cycle.

How to use the queue result

Run the queue with a normal week, a peak week and an ugly week. If a purchase only fits the optimistic case, it is not capacity—it is hope. Use measured minutes per 1,000 stitches whenever possible and keep a deliberate reserve for rework, rush jobs and downtime.

Best use: paste in the six jobs that made last week difficult. The result is more useful than an abstract monthly-volume estimate because it preserves the actual mix.

What the model intentionally does not claim

It does not model thread breaks, design-specific acceleration, operator walking distance, blank staging, artwork approval or machine-specific cap hardware. Those should be added as conservative buffer or measured into your real run-time assumptions.

FAQ

Mixed-order capacity questions

Why not average all stitch counts?

Averages hide the scheduling penalty from small same-design batches. Queue Lab keeps each job's quantity, stitch count, product type and batch size separate so head utilization is not magically smoothed away.

Can independent heads run different designs?

Yes, separate single-head machines can run unrelated jobs at the same time. The model therefore assigns pieces across separate machine timelines rather than forcing every unit into one synchronized cycle.