Typed, ordered, inspectable
A run is a goal, a plan and a graph of typed steps. Every step has an agent, a tool, a duration and a status, and the whole record is kept per car and work package.
Features
Capability by capability, with the limit on each.
Railira's features are the mechanics of a system that is allowed to touch production: typed runs, a policy engine, named approvals, fused inspection, a twin, genealogy and an audit log. The list below is design scope, not a shipped feature list.
Illustrative scenario: Car 07 of a 4-car metro consist · shell line B · bogie shop · booth 2 · marriage station, one car, one approval gate
Features
What the platform does
Each capability names what it does and where its limit sits.
Limits enforced at call time
Tool allow-lists, per-tool rate and magnitude limits, the approved control-plan envelope, autonomy level, shift, car type and interlock state are evaluated before any recommendation becomes a write.
Named humans at the gate
Heat-input and weld-sequence changes, schedule release and car release wait for the approver the plant names. The request, the evidence and the decision are logged.
Every signal, one estimate of build quality
Weld and coating vision, in-line metrology, torque traces, wiring continuity, brake-test and signaling results fused into one estimate per car, localised to station, work package and shift.
Rehearse before the shift
Candidate weld sequences, geometry strategies, marriage plans and build orders ranked on distortion, fit, cure and takt before the shift starts. Proven plans handed to the agents.
The record of every car
Weld records per joint, geometry scans, torque traces, coating recipe and cure, fit-out checks, marriage interface, approvals, test results and disposition, exportable for acceptance and audit.
Approve, correct, feed back
Body, coating and quality engineers see recommendations with their evidence, approve or correct them, and those corrections train the models.
Append-only, exportable
Every agent action with source evidence, the control-plan envelope, confidence, predicted quality and takt impact, rollback path, approver and car scope.
Every answer cites its source
Retrieval over control plans and PFMEA, EN 15085, IRIS / ISO/TS 22163, TSI, AAR and APTA requirements, torque and wiring specifications, brake-test procedures and coating standards, tenant-isolated.
The craft, written down
Per-plant carbody geometry and weld history and per-cell and per-robot performance memory, versioned and scoped per tenant.
Rare cases, validated
Rare weld defects, coating contamination, geometry deviations, occluded seams and torque-escape cases generated to augment training and validated against real inspection distributions before promotion. Planned.
Many plants, one policy
Model versions promoted by process area with canary rollout and automatic fallback; network policy with per-site override on the Enterprise tier.
Run timeline · scenario
One scenario run, 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.
run_9b4e27
car 07 · 4-car metro consist
illustrative scenario
SUCCEEDED
-
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.
Tool calls · scenario
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.
Where it pays
Four loops, four metrics
Railira is not a dashboard. Each agent closes a loop a plant already measures in rework, repaint, torque escapes and line stoppage minutes. The tables show what each loop watches and what it is allowed to move.
Weld and geometry
Sequence the distortion out before the first seam
Weld parameters, seam vision, thermal signatures, fixture state and laser-tracker geometry are fused at the edge into one live estimate of weld quality and shell geometry. Carbra ranks weld sequences and clamping plans on the twin, recommends the one that holds the door aperture, and leaves heat-input changes to a named engineer.
- Weld defects and geometry drift predicted while the shell is built, not found at fit-out
- EN 15085 weld classes enforced per joint at call time
- Every joint labelled with its downstream geometry and acceptance outcome
agent.weld_structure SUCCEEDED
| Signal | Watches | Moves |
|---|---|---|
| Weld quality | Seam cameras, weld current, thermal | Weld sequence and clamping recommendations |
| Shell geometry | Laser trackers, point clouds | Rework priority, inspection coverage |
| Heat input | Weld parameters per joint | Under engineer approval only |
Bogie and torque
Catch the torque escape before brake test
Press-fit curves, torque traces, bearing and mounting telemetry and station vision are read as the bogie is built. Bogira detects the trace that is out of profile, routes the joint to rework before the brake test and keeps the slot.
- Press-fit and torque anomalies detected per joint, not sampled
- Missing parts, orientation and harness routing checked by vision
- Ride and brake risk predicted from build data
agent.bogie_gear SUCCEEDED
| Signal | Watches | Moves |
|---|---|---|
| Press-fit | Curve per wheelset | Station hold, rework routing |
| Torque | Trace per safety-critical joint | Rework before brake test |
| Completeness | Station vision | Missing-part and routing flags |
Livery and cure
Protect the cure window in the sequence
Booth cameras, film thickness, humidity, temperature and flash time are watched through every pass. Coatyx flags dirt, runs, masking errors and colour breaks before the next coat, and hands the cure window to Taktos as a constraint the sequence cannot break.
- Coating defects found before the next coat, not at acceptance
- Film build and cure predicted from recipe and environment
- Cure windows carried into the line plan
agent.coat_livery SUCCEEDED
| Signal | Watches | Moves |
|---|---|---|
| Surface and film | Booth cameras, thickness gauges | Inspection and rework routing |
| Environment | Humidity, temperature, flash time | Recipe inside the approved spec |
| Cure window | Cure telemetry | Constraint to Line-and-Logistics |
Marriage and takt
Marry on the first lift, on the planned slot
Carbody and bogie scans are compared against the target interface before the lift, fit-out readiness is confirmed, and the marriage is guided inside tolerance. Taktos has already sequenced the car so the bogie, the cure and the test slot line up.
- Interface geometry checked before the lift, not after
- Fit-out, coupler and gangway readiness confirmed in the same record
- Sequence built on live readiness, not static routings
agent.marry_couple SUCCEEDED
| Signal | Watches | Moves |
|---|---|---|
| Interface geometry | Carbody and bogie point clouds | Alignment guidance, hold if out of tolerance |
| Readiness | Fit-out, bogie, coating state | Sequence and buffer plan |
| Test slots | Brake, traction, signaling, ride, haul | Commissioning schedule |
Autonomy
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 |
Accelerated computing
Physical AI, at the station
A seam is welded in seconds and a booth cannot wait for the cloud. Perception has to be local, deterministic and fast, so Railira runs GPU inference at the plant edge and keeps training, simulation and optimisation in the cloud or on-prem.
Edge perception
8 to 32 cameras per process area plus metrology, torque, thermal, robot and booth-instrument streams fused at the plant edge. Sub-50 ms weld and seam alerts and sub-150 ms coating and metrology prompts are the design targets. Jetson Thor is planned for higher sensor density.
Model serving
Weld-defect, geometry-risk, coating-risk, point-cloud and takt-risk models served at the plant edge with per-model versioning and rollback, routed by latency, tenant, sensitivity and cost.
Training
Weld and coating defect vision, metrology classification, control-plan reasoning and FEA-surrogate models fine-tuned on plant data and engineer corrections. 100 to 500 GPU-hours per plant during onboarding is the design target; dedicated capacity is planned.
Train-and-plant twin
As-built carbody, coating, marriage and line-flow twin. Weld distortion, geometry build-up, robot reach, coating coverage and layout simulated before the shift. GPU FEA and point-cloud metrology are the workloads; OVX scale is planned.
Synthetic data
Rare weld defects, coating contamination, geometry deviations, occluded seams and torque-escape cases generated and validated against real inspection distributions before promotion. Planned.
Optimisation
Line sequencing, JIS feeding, AMR and AGV routing, buffer management and commissioning-slot scheduling against live readiness.
Robot cells
Robotic weld, coating and assembly cells and AMR or AGV flow; path variants validated in simulation before release to the floor.
GPU ETL
Telemetry features from weld parameters, metrology, coating readings, torque, non-conformance and takt history for retraining, drift detection and network analytics.
Guardrails
An agent that can change a weld sequence needs a leash
Railira writes to production systems. Every capability is scoped, every write is policy-checked against the approved control plan, and every action is written to an append-only audit log the plant owns.
- Bounded action space. Each agent acts only through an explicit tool allow-list, inside per-tool rate and magnitude limits and the approved control-plan envelope for the car type.
- Policy engine before every write. Autonomy level, shift, car type, interlock state and operator presence are evaluated before a recommendation becomes a write to a robot, MES, torque tool or work package.
- Human-in-the-loop gates. Heat-input and weld-sequence changes, schedule release and car release wait for a named approver. High-risk changes remain human-approved until IRIS, plant and OEM acceptance is earned.
- Immutable audit log. Append-only and exportable. Every action records source evidence, the control-plan envelope, confidence, estimated quality and takt impact, rollback path, approver and car scope.
- Hard fallback. Loss of the edge node, the network or a model returns control to the robot, PLC or station's last known-good state. Safety systems and interlocks are never in Railira's path.
- Tenant and program isolation. Designs, control plans, program data, models and memory never cross a customer boundary. On-prem and plant-edge deployment is available for regulated plants.
Compliance posture
| Item | Scope | Status |
|---|---|---|
| SOC 2 Type I and OEM cyber review | Cloud control plane | QUEUED Planned, first 6 months |
| SOC 2 Type II | Cloud control plane | QUEUED Planned, 6 to 12 months |
| SSO and RBAC | Console and approvals | QUEUED Planned, 6 to 12 months |
| IRIS and regulatory assurance packages | Disposition and genealogy evidence | QUEUED Planned, 6 to 12 months; not a certification claim |
| Standards-cited reasoning | Control plans, EN 15085, IRIS / ISO/TS 22163, TSI, AAR, APTA, torque and brake-test procedures | RUNNING In the design, every answer cites its source |
| Per-tenant and program isolation | Designs, control plans, models, memory | RUNNING In the design from day one |
| On-prem and plant-edge deployment | Regulated plants | RUNNING Design option |
FAQ
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.
Get started
See the features on one process
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.