Every rolling-stock plant already measures weld rework, repaint, torque escapes, line stoppage minutes and first-time-through. Railira lands on one of those numbers, on one process, with a baseline agreed in writing, and expands when it moves.
Illustrative scenario: Car 07 of a 4-car metro consist · shell line B · bogie shop · booth 2 · marriage station, one car, one approval gate
The first paid pilot targets one of these. The metric column is what the pilot would be judged on.
Predict weld defects and geometry drift as the shell is built, rank weld sequences on the twin, hold door apertures inside tolerance. Metric: weld rework and geometry escapes against the body-shop baseline.
Read press-fit curves and torque traces per joint, catch the escape before brake test, verify mounting and completeness by vision. Metric: press-fit and torque escapes caught before test.
Flag dirt, runs, masking errors and colour breaks before the next coat and carry the cure window into the sequence. Metric: final-livery defects and repaint events against the coating-shop baseline.
Check interface geometry before the lift, confirm fit-out readiness, guide the marriage, write the as-built interface to the twin. Metric: marriage and fit-out rework against baseline.
Sequence variant-rich production against live readiness, feed kits just in sequence, route AMRs, schedule brake, traction, signaling, ride and haul tests. Metric: line stoppage minutes and test-slot conflicts.
Rehearse weld sequences, geometry strategies, coating coverage, marriage fit and build order on the as-built twin and discard candidates that breach tolerance or cure. Metric: first-time-through and delivery risk.
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 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.
| 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 |
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.
| 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 |
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.
| 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 |
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.
| 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 |
Locomotives, high-speed and intercity trainsets, metro and commuter cars, passenger coaches, freight wagons. Most plants pick one process and one wedge, prove the number, then expand.
Locomotive carbody and underframe shops with large welded structures and propulsion integration. Carbra on the shell line first, where weld rework and geometry escapes are already counted.
Aluminium extrusion shells, tight door-aperture tolerances and ride-quality acceptance. Carbra and Bogira together, with Fitura on the marriage station.
Variant-rich, long-cycle lines where a missed bogie or cure window breaks delivery cadence. Taktos on the shift plan, Coatyx on the booth.
Interior fit-out, accessibility requirements and class-A livery. Fitura on fit-out and Coatyx on livery, with the conformance record from day one.
High-volume welded structures and running-gear assembly at rate. Carbra and Bogira where the torque and weld records already exist.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
We have no customer quotes to show yet and will not invent any. These are the three roles in a rolling-stock plant we build for, and the problems they bring to the first meeting.
What this person is dealing with today
What this person is dealing with today
What this person is dealing with today
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 |
Land on one workflow with a measured baseline. Expand by process, module and autonomy level. Outcome components are available on rework, line uptime, first-time-through and takt. Annual prepay carries a 15 to 20% discount.
Carbody, coating or assembly autonomy or inspection AI for one process. For plants validating ROI on the wedge.
The whole plant: weld and structure, carbody and join, geometry and framing, coat and livery, marry and couple, fit-out and interior, quality and anomaly, line and logistics, and the twin.
Multi-plant OEM and tier-1 networks standardising on Railira, with custom carbody, coating, torque and takt models and a plant-edge fleet.
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.
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.
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