Plant readiness checklist
Network segmentation, OT access, sensor mounting positions at the press exit, power and cooling for edge compute, and the data you need before day one.
Documentation
From first connectorto bounded autonomy.
Everything a plant engineering team needs to install the edge runtime, connect the line, define envelopes, run shadow mode, promote to assist, and export the audit trail.
Full documentation is provided to customers and design partners. This page summarises its structure.
Start here
The first week,documented.
Installing the edge runtime
K3s on-site deployment or IGX appliance, runtime provisioning, tenant enrolment, certificate handling and OTA update policy.
Connecting the press
OPC UA and Modbus tag mapping for ram speed, pressure and position, container and die thermocouples, and furnace zone setpoints.
Sensing at the exit
Camera selection and placement for line-scan and RGB, thermal imaging alignment, laser-gauge calibration and synchronisation across streams.
Defining envelopes
Declaring min, max and max-step per setpoint, approval requirements, alarm interlocks and the sign-off workflow for widening an envelope.
Running shadow mode
Scoring predictions against operators and gauges, reading the accuracy report, and the criteria for promoting to assist mode.
Quickstart
Connect one pressin three files.
A minimal deployment declares the press, its sources, its envelopes and its autonomy mode. Everything else is defaults you can override later.
- Declarative and version-controlled.
- Validated against the twin before promotion.
- Reviewable by OT and safety before anything runs.
# 1. provision the edge runtime on the plant network
extruon edge init --tenant "nordhaus" --site "plant2"
# 2. declare the press, its sources and its envelopes
extruon apply -f press/plant2-press3.yaml
extruon apply -f envelopes/plant2-press3.yaml
# 3. start in shadow — no write path exists in this mode
extruon autonomy set plant2-press3 --mode shadow
# 4. watch predictions score against your gauges
extruon score plant2-press3 --window 14d --against gauge,operatorDocumentation map
Six sections,one deployment path.
Deployment
Edge runtime installation, network and OT requirements, on-prem topology, high availability and OTA update policy.
Connectors
Press PLC, billet-heating furnace, gauge and vision, quench, stretcher, saw, aging oven and MES tag mapping and write-path configuration.
Configuration
Envelopes, approval policy, orchestrator weights, alloy and die registration, and profile tolerance definitions.
Operations
Review console workflows, approval and correction, exception handling, degraded-perception behaviour and shift handover.
Quality & audit
Per-rack traceability, EN 755 and ASTM B221 records, audit-log schema and export to your own object storage.
Models & evaluation
Model versioning, golden datasets, twin validation, promotion gates and how corrections enter the training loop.
Promotion
Moving a pressup the ladder.
Promotion requires evidence. The CLI refuses to advance a press whose accuracy or approval rate has not met the configured gate.
- Accuracy gate against gauge and operator baselines.
- Approval-rate gate from the review console.
- Twin validation gate on the current policy build.
$ extruon autonomy set plant2-press3 --mode bounded
checking gates
dimension accuracy vs gauge 0.94 ≥ 0.90 pass
defect precision / recall 0.91 / 0.88 ≥ 0.85 pass
approval rate (last 500 moves) 0.86 ≥ 0.80 pass
twin validation (policy v14) pass
envelope signatures process-engineering, plant-safety pass
promoted plant2-press3 → bounded autonomy
# writable: ram_speed, exit_temp_target
# approval still required: quench_rate
# rollback: on_alarm · logged: audit://plant2/press3/What the docs describe
Documentation endswhere the metal starts.
Every guide exists to get one thing right: a safe, reviewable, reversible path between your engineers' intent and the ram.
Guides are versioned alongside the runtime, so the doc always matches the build you are running.
Requirements
What the plantneeds to provide.
| Requirement | Typical | Notes |
|---|---|---|
| Press interface | OPC UA or Modbus TCP | Ram speed, pressure, position; container and die temperatures |
| Furnace interface | OPC UA zone setpoints | Taper control requires writable zone targets for bounded autonomy |
| Exit sensing | 4–8 synchronised streams | Line-scan / RGB, thermal, laser gauge — supplied if not present |
| Edge compute | Jetson or IGX class | Sized per press and sensor count during the assessment |
| Network | Segmented OT VLAN | Outbound optional; on-prem mode requires none |
| Identity | SAML or OIDC | For console access and approval accountability |
| Records access | MES and quality exports | Needed for the baseline and the audited delta |
Operations
Runbooks forthe shifts that matter.
Degraded perception
What happens when a camera fails, a gauge drops out or a thermocouple drifts: automatic fall-back to advisory, console banner, audit entry, and the checks before resuming.
Alarm and rollback
Interlock behaviour, last-move reversion, handback to the existing fail-safe stop, and the post-event review the audit trail supports.
New die introduction
Registering a die, running twin sweeps, applying pre-corrections, and how proving pushes are counted against the die-trial metric.
Alloy or temper change
Registering a new alloy and temper target, cold-start behaviour for models, and the shadow period before recommendations resume.
Shift handover
What the console shows at handover: open exceptions, envelope state, pending approvals and the shift's recovery and reject summary.
Quality audit export
Producing per-rack traceability and the signed audit export for an OEM or certification audit.
Docs FAQ
Before youopen a ticket.
The API reference and integration guides are available to customers, design partners and sandbox users. Deployment and safety documentation is provided under the engagement because it references plant-specific configuration.
Edge runtime updates ship through staged OTA with safe rollback, and documentation is versioned alongside the build so the guide always matches what is running.
Not in v1. Enterprise onboarding is sales-assisted and engineering-supported by design, because the first deployment defines the safety envelopes.
In the quality and audit section, alongside the Parquet export definition. The schema is fixed and versioned so downstream BI does not break.
Measured on the press
What you will bereading in the console.
Every Extruon engagement starts with a baseline and ends with an audited delta. These are the target bands we underwrite in a paid pilot.
+4.2 pts
Press recovery uplift, saleable vs charged metal
−38%
Surface-defect and dimensional rejects
−61%
Die-trial pushes before a die is signed off
−12%
kWh per tonne across heating, quench and aging
Target outcome bands modelled from design-partner baselines. [ASPIRATIONAL — to be replaced with audited pilot results.]
Docs
Read it beforeyou install it.
Request the plant readiness checklist and the integration guides, and get sandbox access to build against a simulated press.
Land on one press. Expand press by press, module by module, site by site.