Three walk-throughs. All of them labelled scenarios.
Railira has no customer results yet, so this page does not pretend to. Each scenario describes a hypothetical line, what the agent would do at each autonomy level, and the metric table the pilot would fill in. When a design partner signs, the first real case study replaces the first scenario.
Illustrative scenario: Car 07 of a 4-car metro consist · shell line B · bogie shop · booth 2 · marriage station, one car, one approval gate
Holding the door aperture on an aluminium shell line
A hypothetical metro carbody line welding aluminium extrusion shells to EN 15085: robotic roof-to-sidewall seams, laser-tracker geometry checks, a 1.5 mm door-aperture tolerance. Today the standing weld procedure runs hot to guarantee penetration, and distortion is reworked out at fit-out.
What the agent would do
- Shadow mode. Carbra reads weld parameters, seam vision, thermal and tracker geometry and scores weld-defect and geometry-drift risk per joint; the twin ranks candidate sequences without anything changing on the line.
- Assist mode. Carbra proposes a weld sequence and clamping plan ranked on the twin; the weld engineer approves each heat-input change.
- Bounded autonomy. inspection coverage and rework priority execute inside declared limits; every heat-input and sequence change stays with the engineer.
| Metric | How | Result |
|---|---|---|
| Weld rework | repairs per shell, by joint class | to be measured |
| Geometry escapes | apertures outside tolerance found at fit-out | to be measured |
| Heat input | per joint against the standing procedure | to be measured |
| Inspection coverage | seams inspected per shell | to be measured |
No result is claimed. The metric table is what the pilot would record.
Catching the torque escape before brake test
A hypothetical bogie shop assembling metro trucks: wheelset press-fit, traction-motor and gearbox mounting, brake rigging, torque tools with trace export. Today torque is sampled and an escape is found at brake test or in service.
What the agent would do
- Shadow mode. Bogira reads press-fit curves and torque traces per joint and station vision, and compares its anomaly calls against brake-test and inspection outcomes.
- Assist mode. Bogira flags out-of-profile traces, routes the joint to rework and drafts the cited record; the technician and quality engineer decide.
- Bounded autonomy. station holds and rework routing execute automatically; torque-to-spec stays with the tool and the work instruction.
| Metric | How | Result |
|---|---|---|
| Torque escapes | found at or after brake test, before and during | to be measured |
| Press-fit anomalies | per wheelset, against inspection | to be measured |
| Completeness defects | missing parts and routing faults per bogie | to be measured |
| Genealogy completeness | % of bogies with a full record | to be measured |
No result is claimed. The metric table is what the pilot would record.
Protecting the cure window on a coach livery line
A hypothetical passenger-coach coating shop: surface prep, primer, two livery coats and an anti-graffiti clear, booth cameras, thickness gauges and environmental sensors. Today masking faults are found after the coat and the sequence breaks cure windows to hold test slots.
What the agent would do
- Shadow mode. Coatyx watches booth cameras, film thickness, humidity, temperature and flash time and compares its defect and cure predictions against repaint records.
- Assist mode. Coatyx flags dirt, runs, masking errors and colour breaks before the next coat and hands the cure window to Taktos as a constraint; the coating engineer approves recipe moves.
- Bounded autonomy. inspection and rework routing execute automatically; the sequence treats the cure window as a hard constraint.
| Metric | How | Result |
|---|---|---|
| Repaint events | per car, before and during | to be measured |
| Coating defects | found before the next coat, against acceptance | to be measured |
| Cure-window breaches | per shift | to be measured |
| Film build conformance | % of panels inside spec | to be measured |
No result is claimed. The metric table is what the pilot would record.
The reference scenario, step by step
Every Railira run is an ordered, inspectable sequence. This is run_9b4e27: Car 07 of a 4-car metro consist · shell line B · bogie shop · booth 2 · marriage station. Scenario completes in 10 steps with one approval gate. Shell geometry held inside tolerance after a twin-ranked weld sequence, one heat-input change approved by the shift weld engineer, two torque traces routed to rework before brake test, the livery cure window protected in the sequence, marriage interface inside tolerance, car released with full genealogy.
-
01
ingest.order
SUCCEEDED
0.8 s
Plant Orchestrator · Pulled the work packages for car 07 from MES and PLM: aluminium extrusion shell, EN 15085 weld class per joint, control-plan geometry tolerances, bogie torque specifications, livery recipe and cure window, fit-out and marriage sequence. Locked the approved control-plan envelope for the shift.
-
02
takt.sequence
SUCCEEDED
41 s
Line-and-Logistics · Sequenced the shift against live readiness: booth 2 cure window, bogie B-14 readiness, brake-test slot at 13:40, AMR fleet state and kit inventory. The plan moves car 07 marriage behind car 06 to keep the cure window and the test slot.
-
03
twin.simulate
SUCCEEDED
58 s
Train Twin · Simulated 18 candidate weld sequences for the roof-to-sidewall joints on the as-built twin and ranked them on predicted distortion, door-aperture geometry and heat input. Sequence #6 keeps the aperture inside tolerance with 2% less heat input than the standing sequence.
-
04
weld.sequence
SUCCEEDED
3 m 12 s
Weld-and-Structure · Recommended sequence #6 and the matching clamping plan to the shell line. Seam vision and laser-tracker geometry confirmed the roof-to-sidewall joints inside the control-plan tolerance on the first four seams.
-
05
approve.human
APPROVAL
52 s
Plant Orchestrator · Sequence #6 lowers heat input on the roof joints 2% below the standing weld procedure. Heat-input changes stay with a named engineer, so the step was held for the shift weld engineer and approved at 06:12:44 with the twin evidence attached.
-
06
bogie.torque
SUCCEEDED
continuous
Bogie-and-Running-Gear · Press-fit curves and torque traces on bogie B-14 read at the station. Two traction-motor mounting traces fell outside the expected profile and were routed to rework before brake test; the remaining safety-critical joints verified to spec.
-
07
coat.cure
SUCCEEDED
continuous
Coat-and-Livery · Booth 2 humidity and temperature, film thickness and flash time watched through the livery pass. One masking misalignment on the door band flagged by booth vision before the second coat; the cure window held and handed to the sequence as a hard constraint.
-
08
marry.align
SUCCEEDED
2 m 05 s
Marry-and-Couple · Carbody and bogie scans compared against target interface geometry before the lift. Fit-out readiness confirmed by Fitout-and-Interior for doors and glazing. Marriage guided inside tolerance; coupler and gangway checks verified and written to the twin.
-
09
inspect.fuse
SUCCEEDED
continuous
Quality-and-Anomaly · Weld and coating vision, in-line metrology, torque, wiring continuity and brake-test results fused at the edge across the car. Every finding localised to station, work package and shift, with the two torque reworks and the masking flag already closed.
-
10
car.release
SUCCEEDED
1 m 30 s
Conformance · Car 07 released: genealogy written (weld records per joint, geometry scans, torque traces, coating recipe and cure record, fit-out checks, marriage interface, approvals, test results) and dispositioned against the control plan and IRIS / ISO/TS 22163 criteria with cited evidence for the quality engineer's sign-off.
The agent shows its work
Every tool invocation, argument and result is written to an append-only, human-readable log, and every reasoning step is expandable. Nothing about a run is hidden from the plant.
- 05:58:02mes.read_workpackages({ car: "07", consist: "M4-118", shift: "A" })
- 05:58:03ok 142 work packages · control plan locked · EN 15085 classes mapped
- 05:58:04cuopt.sequence({ shift: "A", constraints: ["cure_window", "test_slot", "bogie_ready"] })
- 05:58:45ok plan released · car 07 marriage after car 06 · test slot 13:40 held
- 05:58:46twin.simulate({ joints: "roof-sidewall", candidates: 18 })
- 05:59:44ok best sequence #6 · aperture dev 0.6 mm · heat input −2%
- 05:59:45policy.evaluate({ sequence: 6, autonomy: "L2+" })
- 05:59:45ok 6 recommendations permitted · heat_input requires human approval
- 05:59:46weld.set_sequence({ line: "B", seq: 6, clamping: "plan-6" })
- 06:02:58ok 4 seams inside tolerance · tracker dev 0.5 mm
- 06:02:59approval.request({ action: "heat_input", delta: "-2%", joints: "roof" })
- 06:12:44ok approved by shift weld engineer · twin evidence attached · logged
- 06:12:45torque.read_trace({ bogie: "B-14", joints: "all" })
- 07:40:12trace out of profile · traction-motor mount M3, M4 · bogie B-14
- 07:40:13rework.route({ bogie: "B-14", joints: ["M3", "M4"], before: "brake_test" })
- 07:40:13ok routed · brake test slot held
- 08:05:00cure.window({ booth: 2, recipe: "livery-M4" })
- 08:31:20masking misalignment · door band · booth 2 · before coat 2
- 08:31:21ok masking corrected · cure window held · constraint sent to sequence
- 11:10:02scan.compare({ car: "07", bogie: "B-14" })
- 11:12:07ok interface inside tolerance · fit-out ready · marriage guided
- 11:12:08sensors.fuse({ car: "07", streams: ["vision", "metrology", "torque", "wiring"] })
- 13:58:40genealogy.write({ car: "07", packets: "full" })
- 14:00:10ok scenario complete · 10 steps · car 07 released
Reasoning trace
Plan, thought, action, observation, exactly as the orchestrator would record it.
GoalBuild car 07 through shell welding, bogie assembly, livery, fi…
Build car 07 through shell welding, bogie assembly, livery, fit-out and marriage on the shift plan, inside the control plan, with every safety-critical joint to spec and the cure window protected.
PlanSequence the shift first, so the cure window and the brake-tes…
Sequence the shift first, so the cure window and the brake-test slot are protected. Simulate the roof-to-sidewall weld sequence on the twin before the first seam. Read every torque trace at the station. Fuse inspection continuously. Hold any heat-input change for a human.
ThoughtThe standing weld procedure runs the roof joints hot enough to…
The standing weld procedure runs the roof joints hot enough to guarantee penetration on a cold fixture. With the clamping plan from the twin the same penetration holds at 2% less heat input and the door aperture stays inside tolerance, because the distortion is sequenced out rather than reworked out.
Actiontwin.simulate(candidates=18) returns sequence #6: roof joints …
twin.simulate(candidates=18) returns sequence #6: roof joints re-ordered, clamping plan 6, heat input down 2% on the roof joints.
ObservationSequence #6 predicts door-aperture deviation 0.6 mm against a …
Sequence #6 predicts door-aperture deviation 0.6 mm against a 1.5 mm tolerance. Three candidates scored lower on heat input but pushed predicted sidewall distortion past the limit and were discarded.
ActionRecommend sequence #6 to the shell line; six recommendations p…
Recommend sequence #6 to the shell line; six recommendations permitted; the heat-input change routed to the shift weld engineer with the twin evidence.
ObservationTwo traction-motor mounting traces on bogie B-14 fell outside …
Two traction-motor mounting traces on bogie B-14 fell outside the expected profile at 07:40:12. Routed to rework before brake test; the slot held. One masking misalignment on the door band flagged in booth 2 before the second coat.
OutcomeScenario complete. Shell inside tolerance, bogie joints to spe…
Scenario complete. Shell inside tolerance, bogie joints to spec after rework, livery inside the cure window, marriage interface inside tolerance. Car 07 released with full genealogy.
Four levels, set per agent and per tool
A rolling-stock plant does not go from manual to unattended in one step. Railira makes the level explicit, auditable and reversible at any time. The first release runs shadow mode, then assist mode, then bounded autonomy on low-risk actions. Weld parameters, schedule release and car release stay with named humans until acceptance is earned.
| Level | What the agent does | What the human does | Where it sits in a pilot |
|---|---|---|---|
| L1 · Shadow | Reads weld, metrology, torque, coating, wiring, test, robot and MES signals; predicts and recommends; writes nothing | Runs the line as today; compares predictions to inspection and engineer outcomes | Shadow mode; baseline measured from the plant's own records |
| L2 · Assist | Proposes weld-sequence, geometry, coating, torque and sequencing moves with evidence, confidence, envelope and rollback path | Approves each move in the review console | Assist mode; accuracy and ROI proven against the baseline |
| L3 · Bounded | Executes pre-approved low-risk actions: inspection routing, rework priority, kit feeding, robot path variants and parameter adjustments inside approved bounds | Approves heat-input and weld-sequence changes, schedule release and car release | Graduated autonomy, after audited accuracy and ROI and safety gates |
| L4 · Scaled | Supervised weld-parameter adaptation inside pre-approved control-plan envelopes, across lines and plants | Sets the envelope; reviews the shift record and the evaluation results | Planned; after IRIS, plant and OEM acceptance is earned |
Straight answers
The questions plant directors, body and coating engineers and quality leads ask in the first meeting.
Only within an explicit tool allow-list with per-tool rate and magnitude limits, inside the approved control-plan envelope, and only at the autonomy level your plant has set. Design partners start in shadow mode, where Railira writes nothing. Heat-input and weld-sequence changes, schedule release and car release stay with a named approver.
Control returns to the robot, PLC or station's last known-good state. Railira is a supervisory layer on top of the controllers, safety systems and interlocks you already run, never a replacement for them, so an outage degrades the line to its current way of running, not to a stop.
Recommendations start from the control plan, the work instructions and the twin in the first weeks. Weld, geometry, coating and torque prediction improve as line history and labelled outcomes accumulate per car type. Onboarding is sized at 100 to 500 GPU-hours per plant and 50,000 to 250,000 synthetic images or scan variants per program, all design targets.
Only if you choose cloud training. Designs, control plans, program data, process models and quality records are isolated per tenant and never used to train another customer's models. Fully on-prem deployment at the plant edge is available for regulated plants, and cross-plant learning is planned and waits on data-rights agreements.
You are, the same as with any control strategy, which is why every write is policy-checked, bounded, logged and reversible, and why anything above your risk threshold waits for a named approver. The audit log records the request, the evidence, the envelope applied and the human decision.
A paid pilot on one process or line area, scoped to a single wedge with a success metric written into the order form: weld or coating rework reduction, geometry escapes, torque escapes, line stoppage minutes or first-time-through. It starts in shadow mode against a baseline from your own records, moves to assist mode when the engineer is satisfied, and expands only after the number moves.
Make the first scenario real
Start with one carbody, bogie, coating, fit-out or sequencing process and one measurable baseline. A paid pilot on weld and geometry, torque assurance, livery defects or line sequencing shows the number before you commit further.