Rail PLM, MES and sequencing suites (Siemens Teamcenter, Opcenter and Tecnomatix, Dassault DELMIA, Rockwell, iBASEt, Critical Manufacturing class systems)
Work packages, control plans, sequence reads; genealogy and schedule write-back
Integrations
It reads your plant. It does not replace it.
Railira connects to the PLM, MES, welding and coating robots, laser trackers and scanners, torque tools, wiring testers, brake-test rigs, commissioning systems, coating booths and AMR fleets already in a rolling-stock plant and normalises their signals into one time-aligned car and work-package record. Writes go back through the same systems, guarded.
Illustrative scenario: Car 07 of a 4-car metro consist · shell line B · bogie shop · booth 2 · marriage station, one car, one approval gate
Integrations
It speaks plant, not cloud
Railira reads and writes through the systems already on the floor. No rip and replace, no parallel historian, no new HMI to learn. Vendor names are examples of systems found in rolling-stock plants, not certified integrations; connector availability is confirmed per site.
Robot controllers and process controllers (FANUC, KUKA, ABB, Yaskawa, Comau, Dürr, Kawasaki class systems)
Parameter and path reads; bounded parameter and sequence recommendations
Laser trackers, point-cloud scanners and vision systems (Hexagon, Zeiss, FARO, Cognex, ISRA Vision, Perceptron class systems)
Geometry scans and inspection results per car
Torque tools and controllers (Atlas Copco, Bosch Rexroth, Stanley class systems)
Torque traces per joint, rework routing
Wiring testers, brake-test rigs, traction-test and ETCS, ERTMS or PTC commissioning systems
Continuity, brake and signaling results per car
Booth instruments, thickness gauges, environmental sensors, recipe systems
Film build, flash, cure, humidity and temperature
Plant-simulation and twin tools (Siemens Tecnomatix Plant Simulation, Dassault DELMIA, Visual Components)
Model and result exchange with the train-and-plant twin
Fleet managers and dispatch APIs
Fleet state, dispatch recommendations
Quality systems, PPAP and non-conformance records
Disposition, genealogy, acceptance evidence
Time-series store for telemetry, pgvector for defect and scan images, control plans and standards
Backfill, replay, retrieval
NVIDIA Jetson Orin at the station, on-prem GPU in the plant
Inference where the car is built
Compatibility
Systems and what we do with them
Vendor names are examples of the systems found in rolling-stock plants, not certified integrations. Connector availability is confirmed during the shadow-mode phase of a pilot.
| Category | Examples in the plant | What Railira does |
|---|---|---|
| PLM, MES and line sequencing | Rail PLM, MES and sequencing suites (Siemens Teamcenter, Opcenter and Tecnomatix, Dassault DELMIA, Rockwell, iBASEt, Critical Manufacturing class systems) | Work packages, control plans, sequence reads; genealogy and schedule write-back |
| Welding and coating robots | Robot controllers and process controllers (FANUC, KUKA, ABB, Yaskawa, Comau, Dürr, Kawasaki class systems) | Parameter and path reads; bounded parameter and sequence recommendations |
| In-line metrology | Laser trackers, point-cloud scanners and vision systems (Hexagon, Zeiss, FARO, Cognex, ISRA Vision, Perceptron class systems) | Geometry scans and inspection results per car |
| Torque and error-proofing | Torque tools and controllers (Atlas Copco, Bosch Rexroth, Stanley class systems) | Torque traces per joint, rework routing |
| Wiring, brake and commissioning | Wiring testers, brake-test rigs, traction-test and ETCS, ERTMS or PTC commissioning systems | Continuity, brake and signaling results per car |
| Coating booths | Booth instruments, thickness gauges, environmental sensors, recipe systems | Film build, flash, cure, humidity and temperature |
| Plant simulation | Plant-simulation and twin tools (Siemens Tecnomatix Plant Simulation, Dassault DELMIA, Visual Components) | Model and result exchange with the train-and-plant twin |
| AMR and AGV fleets | Fleet managers and dispatch APIs | Fleet state, dispatch recommendations |
| Quality and QMS | Quality systems, PPAP and non-conformance records | Disposition, genealogy, acceptance evidence |
| Historian and stores | Time-series store for telemetry, pgvector for defect and scan images, control plans and standards | Backfill, replay, retrieval |
| Edge | NVIDIA Jetson Orin at the station, on-prem GPU in the plant | Inference where the car is built |
Connection
How a process gets connected
The shadow-mode phase of a pilot.
- Inventory. List the PLM, MES, robot, metrology, torque, test, booth and AMR systems on the wedge process, with their interfaces.
- Read-only first. Connect every source read-only and build the time-aligned car and work-package record. No writes exist yet.
- Baseline. Measure the agreed metric from the plant's own records.
- Declare the tools and the envelope. Agree the tool allow-list, limits, control-plan envelope and approvers before any write is enabled.
- Assist, then bounded. Writes begin on approval, then inside limits for low-risk actions, as the autonomy level is raised. Weld parameters stay with the engineer.
Boundaries
What Railira deliberately does not do
Scope limits in version one.
- Replace the PLC, robot controller, safety system or interlocks. Railira is a supervisory layer on top of them.
- Write to any target that is not on the allow-list, or outside its declared limits and envelope.
- Change a weld procedure or heat input without a named engineer's approval.
- Run full multi-process autonomy across the whole plant or network in version one.
- Build long-tail integrations beyond the design partners' stacks before they are needed.
- Move designs, control plans or program data across tenants.
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.
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
Check your stack
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.