Spin-and-Yarn
Spinning, count, twist & yarn quality
Controls draft, twist and speed across ring, rotor and air-jet frames to hold count (Ne), CV%, twist and tenacity inside buyer spec, and predicts end-breaks before they cascade.
The roster
Nine agents that each own a machine
Not nine chatbots. Nine bounded controllers, each with its own sensors, its own actuators, its own watched metric and its own autonomy ceiling.
The agent roster
Nine agents, one mill orchestrator
Each agent owns a stage of the mill, senses its own signals and actuates its own setpoints. The orchestrator plans across them, escalates on policy, and keeps one record of the whole run.
Weave-and-Knit
Loom & knitting-machine control
Holds warp and weft tension, pick density, let-off and take-up on air-jet, rapier and circular-knit machines so construction stays on spec without broken picks, ends-out, floats or holes.
Dye-and-Color
Dyeing chemistry, recipe & shade
Predicts and doses dye recipes from substrate state, then closes the loop on exhaust curves, temperature ramps, pH and salt so the lot lands on shade first time instead of after two re-dyes.
Finish-and-Hand
Finishing chemistry, hand & stability
Controls stenter chemistry, overfeed, residence and temperature to hit hand, GSM, width and dimensional stability, with shrinkage and skew held to buyer tolerance across the roll.
Defect-and-Inspect
Vision fabric-defect sensing
Line-scan and NIR vision detects and classifies slubs, holes, streaks, stains, floats, barré, skew and width faults in-line at full loom and stenter speed, then maps every fault to roll position.
Shade-and-Quality
Colour, fastness & grade optimisation
Spectral models score every roll against the buyer standard (ΔE, metamerism, fastness risk) and sort rolls into shade bands so cutting rooms never mix two shades in one garment.
Yield-and-Takt
Yield, waste, water, energy & balancing
Sequences dye lots and balances the line against takt, then allocates water, steam and electricity to cut the mill’s two biggest costs after fibre, reprocessing and utilities.
Robot-and-Handling
Roll, beam & doffing automation
Drives doffing, beam changes and roll transport with vision-guided manipulators and AMRs, so the scarce labour on the floor moves from lifting rolls to supervising the run.
Quality-and-Conformance
Right-first-time, genealogy & traceability
Keeps immutable roll genealogy from bale to bolt and assembles the conformance packet, test methods, chemistry declarations and audit trail, that buyers and auditors demand.
Text equivalent
What each agent senses and actuates
The same roster as a table, because an agent that will move a setpoint on your machine should be legible in plain rows before it is legible in a diagram.
| Agent | Senses | Actuates | Metric watched |
|---|---|---|---|
| Spin-and-Yarn | Evenness (Uster CVm%) · Imperfections IPI /km · Twist per inch · End-break rate · Roving/draft state | Draft ratio · Spindle speed · Twist multiplier · Doffing schedule | Watches: yarn IPI and CV% variance |
| Weave-and-Knit | Warp tension curve · Pick/course density · Stop causes · Loom efficiency % · Beam depletion | Let-off / take-up · Machine speed · Tension setpoints · Stop-and-repair routing | Watches: loom stops and construction faults |
| Dye-and-Color | Bath spectrophotometry · Exhaustion curve · Liquor ratio, pH, conductivity · Temperature ramp | Dosing schedule · Ramp rate & hold · Salt/alkali addition · Sampling & release | Watches: right-first-time shade |
| Finish-and-Hand | GSM, width, overfeed · Residual shrinkage · Handle/stiffness proxy · Curing temperature profile | Pad-bath concentration · Overfeed & pin width · Line speed · Curing profile | Watches: shrinkage and width out of tolerance |
| Defect-and-Inspect | Line-scan RGB + NIR frames · Defect class & severity · Metres between faults · Roll position map | Stop / slow line · Cut-plan marking · Rework routing · Grade assignment | Watches: defect escape rate |
| Shade-and-Quality | ΔE 2000 vs standard · Metamerism index · Fastness test history · Shade band assignment | Shade banding · Release / hold / re-dye · Buyer submission packet | Watches: shade-related chargebacks |
| Yield-and-Takt | Takt vs actual per stage · Litres water / kg fabric · kWh & steam per lot · Seconds & waste % | Dye-lot sequence · Machine assignment · Rework queue · Utility allocation | Watches: water and steam per kg |
| Robot-and-Handling | Roll/beam pose estimate · Gripper force feedback · AMR fleet state · Handling queue depth | Doff & beam-change cycles · Roll transport moves · Package palletising | Watches: manual handling hours |
| Quality-and-Conformance | Roll genealogy graph · Non-conformance records · AATCC/ISO test results · Chemistry declarations | Hold / release decisions · CAPA creation · Buyer & audit packet export | Watches: audit packet assembly time |
Products
Which product each agent ships in
The nine agents are packaged as six products. Vireon carries perception, Spindra, Loomix and Shadeon carry the production stages, Doffex carries handling, and Twinly carries the twin. Conformance runs in the platform itself.
Vireon
Mill-edge vision that sees every defect on the roll before the buyer does.
Spindra
Autonomous spinning that holds count, twist and evenness, roll after roll.
Loomix
Autonomous weaving and knitting that stops the fault before the pick.
Shadeon
Right-first-time dyeing. The shade hits before the bath fills.
Doffex
Robotic hands for the mill: doffing, rolls and beams moved without operators.
Twinly
The as-produced fabric twin that hits quality, shade and takt before the run.
Agent graph
One run, ten steps, one human decision
This is the shape of a dye lot on Yarneon, shown as an illustrative scenario rather than a customer run. Ingest and simulation fan out, converge on a colourist approval gate, then dosing, verification, finishing, inspection and release. The accent traces the active path; every node opens in the inspector.
Scroll the graph sideways · or open the text equivalent below
SUCCEEDED APPROVAL FAILED RUNNING
Text equivalent, workflow steps, dependencies and status
| Step | Stage | Depends on | Status | Duration |
|---|---|---|---|---|
| ingest | conformance | none | SUCCEEDED | 0.8s |
| twin | simulate | ingest | SUCCEEDED | 46s |
| recipe | dye + colour | ingest | SUCCEEDED | 2.4s |
| approve | human gate | twin, recipe | APPROVAL | 4m 12s |
| dose | bath control | approve | SUCCEEDED | 118m |
| shade | verify ΔE | dose | SUCCEEDED | 9.1s |
| finish | stenter | dose | SUCCEEDED | 64m |
| inspect | vision | shade, finish | FAILED | 38m |
| rework | replan | inspect | SUCCEEDED | 1.6s |
| grade | release | rework | SUCCEEDED | 3.0s |
- Parallel branches2twin simulation and recipe prediction run together
- Human gates1colourist approval, 15 minutes, attributed
- Failures recovered1weft streak on roll 09, replanned in-run
Run timeline
RUN-4471 · Indigo poplin, 3,180 kg, due Thursday
The same scenario run as an ordered timeline: step, status, duration and the tool result behind it. Inspection failed on one roll, the run recovered, replanned the cut and still held the ship date.
RUN-4471
RUN COMPLETE
Scenario mill · reactive exhaust jet dyeing · illustrative run, not a customer deployment
Goal: Dye lot DL-4471 · 3,180 kg · 40s combed cotton poplin · shade Indigo 19-4028 TCX · ΔE ≤ 0.8 · due Thu 06:00
-
01 ingest.lot_state SUCCEEDED 0.8s
Pulls greige genealogy for 14 rolls: yarn lots, loom, greige GSM 138, absorbency and residual size from the prep line.
Agent, input and output
agent Quality-and-Conformance result ← 14 rolls · 3,180 kg · mean GSM 138.2 (σ 1.1) · prep OK -
02 twin.simulate_lot SUCCEEDED 46s
Omniverse fabric-line twin simulates the exhaust curve, machine loading and takt for three candidate recipes before a drop of dye is used.
Agent, input and output
agent Yield-and-Takt result ← 3 candidates scored · best predicted ΔE 0.52 · 118 min cycle -
03 dye.predict_recipe SUCCEEDED 2.4s
Spectral recipe model proposes a 3-dye combination against the buyer standard, corrected for this substrate’s absorbency and the current water hardness.
Agent, input and output
agent Dye-and-Color result ← 2.14% Navy RGB · 0.61% Blue BRF · 0.08% Black B · salt 62 g/L -
04 human.approve_recipe APPROVAL 4m 12s
Recipe deviates >5% from the standing card, so autonomy is capped: the colourist approves, rejects or edits before any dosing. Guardrail policy MILL-02/DYE-APPROVAL.
Agent, input and output
agent Dye-and-Color result → awaiting colourist · approved on shift 04:18 -
05 dye.control_bath SUCCEEDED 118m
Closed-loop dosing and ramp control against live bath spectrophotometry; two mid-cycle corrections applied when exhaustion ran 4% ahead of model.
Agent, input and output
agent Dye-and-Color result ← exhaust 96.4% · 2 corrections · bath ΔE 0.41 at drain -
06 shade.verify_lot SUCCEEDED 9.1s
Per-roll spectral read against Indigo 19-4028 TCX under D65/TL84/A; metamerism scored and rolls sorted into shade bands.
Agent, input and output
agent Shade-and-Quality result ← mean ΔE 0.58 · 13 rolls band A · 1 roll band B -
07 finish.control_stenter SUCCEEDED 64m
Stenter chemistry, overfeed and curing profile set to hold hand, 148 cm width and residual shrinkage under 3%.
Agent, input and output
agent Finish-and-Hand result ← width 148.3 cm · shrink 2.1% warp / 1.4% weft -
08 inspect.scan_rolls FAILED 38m
In-line vision flags a recurring 6 cm weft streak on roll 09 between 412 m and 445 m, traced to a stenter pin-chain slip, not a dye fault.
Agent, input and output
agent Defect-and-Inspect result ← 1 defect cluster · roll 09 · 33 m affected · class WEFT_STREAK -
09 plan.rework_route SUCCEEDED 1.6s
cuOpt re-plans the cut and rework route: 33 m diverted to seconds, remaining 14,890 m re-sequenced so the buyer’s Thursday ship date still holds.
Agent, input and output
agent Yield-and-Takt result ← 33 m to seconds (0.22%) · ship date held -
10 quality.grade_and_release SUCCEEDED 3.0s
Four-point grading, roll genealogy and the conformance packet (AATCC 61, ISO 105-C06, ZDHC MRSL declaration) are assembled and released to the buyer portal.
Agent, input and output
agent Quality-and-Conformance result ← 13 rolls Grade A · 1 roll Grade B · packet signed
RUN OUTCOME
Lot released first time, on shade, on date.
| Measure | Value | Context |
|---|---|---|
| Final mean ΔE | 0.58 | against a 0.80 tolerance |
| Re-dyes avoided | 1 | the standing card would have missed shade |
| Seconds | 0.22% | versus the scenario mill baseline of 1.9% |
| Water used | 46 L/kg | versus 59 L/kg on the scenario recipe card |
| Human decisions | 1 | the recipe approval gate |
Why this matters
A mill does not fail on the good lots. It fails on the lot where the substrate drifted, the recipe card was wrong, and nobody found out until the buyer opened the carton. Yarneon makes that lot legible while it is still in the machine.
Tool-call stream
Every call the agent made, in order
Machines, spectrophotometers, the optimiser and the humans are all tools. Calls go out, results come back, and the whole exchange is real, copyable text, the same record your auditor sees.
04:02:11
result: mes.get_lot("DL-4471") → 14 rolls · 3,180 kg · poplin 40s
SUCCEEDED
04:02:12
call: twin.simulate(recipe_candidates=3, machine="jet-07")
RUNNING
04:02:58
result: twin.simulate → best ΔE 0.52 · cycle 118 min · water 46 L/kg
SUCCEEDED
04:03:01
call: colour.predict_recipe(substrate="cotton", standard="19-4028 TCX")
RUNNING
04:03:03
result: colour.predict_recipe → Navy RGB 2.14% · Blue BRF 0.61% · Black B 0.08%
SUCCEEDED
04:03:04
call: policy.check(action="dose", deviation=7.2%) → requires human approval
APPROVAL
04:18:22
result: human.approve(user="colourist-on-shift", decision="approve", note="ok, hold ramp")
SUCCEEDED
04:18:24
call: plc.dose(machine="jet-07", schedule="ramp-B")
RUNNING
05:41:07
result: spectro.read(bath) → exhaustion 96.4% · bath ΔE 0.41
SUCCEEDED
06:22:40
result: vision.scan(roll=09) → WEFT_STREAK 412–445 m · severity 3
FAILED
06:22:41
call: cuopt.replan(cut_plan, constraint="ship_thu_0600")
RUNNING
06:22:43
result: cuopt.replan → 33 m to seconds · ship date held
SUCCEEDED
06:25:02
result: quality.release(lot="DL-4471") → 13 Grade A · 1 Grade B · packet signed
SUCCEEDED
Guardrail in action
policy.check → requires human approval
At 04:03:04 the proposed recipe deviated 7.2% from the standing card, above the 5% autonomy ceiling for dye dosing at this mill. The agent stopped and asked. Fifteen minutes later a colourist approved it, and that approval is attributed, timestamped and reversible.
Failure handled honestly
vision.scan → WEFT_STREAK, roll 09
A 33 m weft streak is a real defect, and the run shows it as failed rather than smoothing it over. The mechanical root cause, a stenter pin-chain slip, was correlated automatically and raised as a work order.
Reasoning trace
The reasoning, written down
Goal, observation, plan, action, decision, handoff, outcome. A colourist can read this and disagree with it, which is the point. Autonomy a mill cannot argue with is autonomy a mill will not adopt.
-
Land DL-4471 on Indigo 19-4028 TCX within ΔE 0.80, first time, before the Thursday 06:00 ship cut-off.
-
Greige absorbency for this lot reads 8% above the card baseline, and incoming water hardness is 142 ppm, both push the exhaust curve faster than the standing recipe assumes.
-
Simulate three recipes in the fabric twin before committing dye. Prefer the candidate with the lowest predicted ΔE that also fits the 118-minute machine slot.
-
twin.simulate(recipe_candidates=3, machine="jet-07")
-
Candidate B predicts ΔE 0.52 and finishes 6 minutes inside the slot. Candidates A and C either overshoot shade or miss takt.
-
Candidate B deviates 7.2% from the standing card, above the 5% autonomy ceiling for dye dosing. Escalate to the colourist rather than act.
-
Dye-and-Color → the colourist on shift, with the simulated curve, the deviation reason and a one-click revert attached.
-
plc.dose(machine="jet-07", schedule="ramp-B") after approval, with two mid-cycle corrections when exhaustion led the model by 4%.
-
Vision flags a 33 m weft streak on roll 09 after finishing. Correlating stenter telemetry shows a pin-chain slip at 04:51, a mechanical cause, not a dye fault.
-
Lot released at mean ΔE 0.58 with 0.22% seconds. A maintenance work order is raised against the stenter pin chain, and the streak signature is added to the mill’s defect memory.
Human in the loop
Craft is captured, not replaced
Textile mills run on scarce craft: the colourist who knows this jet runs hot, the weaving master who hears a beam going wrong. That knowledge is retiring faster than it is being replaced.
Yarneon writes it down. Every approval, override and correction becomes per-mill memory scoped to your tenant, so the mill keeps improving after the person who taught it has gone home.
- Per-colourist and per-operator performance memory
- Overrides captured as training signal, not noise
- Versioned memory, scoped per tenant, never shared across mills
Agent profile
Spin-and-Yarn
Controls draft, twist and speed across ring, rotor and air-jet frames to hold count (Ne), CV%, twist and tenacity inside buyer spec, and predicts end-breaks before they cascade.
Spinning, count, twist & yarn quality
Spin-and-Yarn runs continuously on its stage. It is granted autonomy one setpoint at a time, and every move it makes is attributable and reversible.
- Actuates: Draft ratio
- Actuates: Spindle speed
- Actuates: Twist multiplier
- Actuates: Doffing schedule
| Signal | Why it matters |
|---|---|
| Evenness (Uster CVm%) | Fused into the roll-level state stream and the twin. |
| Imperfections IPI /km | Fused into the roll-level state stream and the twin. |
| Twist per inch | Fused into the roll-level state stream and the twin. |
| End-break rate | Fused into the roll-level state stream and the twin. |
| Roving/draft state | Fused into the roll-level state stream and the twin. |
Agent profile
Weave-and-Knit
Holds warp and weft tension, pick density, let-off and take-up on air-jet, rapier and circular-knit machines so construction stays on spec without broken picks, ends-out, floats or holes.
| Signal | Why it matters |
|---|---|
| Warp tension curve | Fused into the roll-level state stream and the twin. |
| Pick/course density | Fused into the roll-level state stream and the twin. |
| Stop causes | Fused into the roll-level state stream and the twin. |
| Loom efficiency % | Fused into the roll-level state stream and the twin. |
| Beam depletion | Fused into the roll-level state stream and the twin. |
Loom & knitting-machine control
Weave-and-Knit runs continuously on its stage. It is granted autonomy one setpoint at a time, and every move it makes is attributable and reversible.
- Actuates: Let-off / take-up
- Actuates: Machine speed
- Actuates: Tension setpoints
- Actuates: Stop-and-repair routing
Agent profile
Dye-and-Color
Predicts and doses dye recipes from substrate state, then closes the loop on exhaust curves, temperature ramps, pH and salt so the lot lands on shade first time instead of after two re-dyes.
Dyeing chemistry, recipe & shade
Dye-and-Color runs continuously on its stage. It is granted autonomy one setpoint at a time, and every move it makes is attributable and reversible.
- Actuates: Dosing schedule
- Actuates: Ramp rate & hold
- Actuates: Salt/alkali addition
- Actuates: Sampling & release
| Signal | Why it matters |
|---|---|
| Bath spectrophotometry | Fused into the roll-level state stream and the twin. |
| Exhaustion curve | Fused into the roll-level state stream and the twin. |
| Liquor ratio, pH, conductivity | Fused into the roll-level state stream and the twin. |
| Temperature ramp | Fused into the roll-level state stream and the twin. |
Use cases
What mills point Yarneon at first
Every deployment starts with one wedge workflow that pays for itself, then expands along the line.
Hold shade on the first dyeing
Substrate-aware recipe prediction plus closed-loop exhaust control, with the colourist approving only what deviates.
Catch defects at the machine
Line-scan and NIR vision classify slubs, holes, streaks, stains, floats, barré and skew at full line speed, mapped to roll position.
Stop end-breaks before they cascade
Evenness and draft telemetry predict end-break clusters on ring frames and adjust before the frame sheds packages.
Keep construction on spec
Warp and weft tension control across air-jet, rapier and circular-knit machines holds pick and course density inside tolerance.
Hit hand, width and shrinkage
Stenter chemistry, overfeed and curing profiles tuned per construction so finished goods pass dimensional-stability tests.
Band rolls by shade before cutting
Spectral scoring sorts rolls into shade bands so no garment is cut from two shades.
Sequence dye lots for water and takt
Shade-family aware sequencing under delivery and machine constraints cuts changeovers, water and steam.
Automate doffing and roll transport
Vision-guided manipulators and AMRs take the lifting out of the job that mills cannot staff.
Produce the buyer packet automatically
Roll genealogy, test methods and chemistry declarations assembled and signed at release.
Guardrails
An agent earns the right to touch a machine
Nothing here is a global "AI on" switch. Autonomy is granted per setpoint, bounded by policy, reversible by any operator and logged permanently.
- Graduated autonomy
- Every workflow moves observe → assist → bounded auto-control. Autonomy ceilings are per-setpoint policy, not a global switch.
- Human-in-the-loop gates
- Approval gates fire on deviation thresholds, new substrates, or any action outside the authorised envelope. Approvals are attributed and time-stamped.
- Reversibility
- Every control action ships with a revert path and a last-known-good setpoint. Operators can take manual control at any moment, from the HMI or the panel.
- Immutable audit log
- Assurance-grade, append-only record of every observation, decision, tool call, approval and actuation, exportable for buyer and regulatory audit.
- Tenant isolation
- Recipes, construction libraries and roll data are isolated per tenant. No cross-tenant training. Permission-aware retrieval with enforced citations.
- Sandboxed tools
- Agents call machines through a typed, scoped tool layer with rate and range limits. There is no path from a model output to an unbounded PLC write.
Trust signals
What the runs actually produce
No customer results are published yet. These are platform facts and plan terms from our own documents. Outcomes will be measured against each mill’s own trailing twelve months, in shadow mode before anything is controlled.
9
Mill agents, one per stage, from spinning to release.
6
Products in the loop: Vireon, Spindra, Loomix, Shadeon, Doffex and Twinly.
3 to 5
Design partners we are onboarding first, one wedge workflow each.
$14k
Per line per month on the Line plan. Mill and Enterprise sit above it.
Items marked ASPIRATIONAL are design targets ahead of production validation.
Questions
What mills ask before they let an agent near a jet
Both, in that order. Every workflow starts in observe mode, graduates to assist (the agent proposes, a human commits), and only then to bounded auto-control on the specific setpoints you authorise. Autonomy ceilings, approval gates and spend limits are policy objects you own, and every action is reversible and logged.
The control loop lives at the mill edge. Inference, guardrails and the audit log run locally on the edge appliance, so a lost uplink degrades reporting and retraining, not machine control. Buffered telemetry syncs when the link returns.
Design partners start with one wedge line in shadow mode: connectors and telemetry first, then models scored against what the mill actually produced, then assist mode where the agent proposes and an engineer approves. Whole-mill rollout follows once the wedge holds its numbers. Durations depend on how instrumented the mill already is, so we quote them after the assessment, not before.
To predict recipes well, yes, and that IP never leaves your tenant. Retrieval is multi-tenant isolated, models fine-tuned on your data are yours, and on-prem deployment is available for groups that will not put recipes in any cloud.
A Jetson-class edge device per inspection or control cell, one GPU server per mill for multi-model serving, line-scan cameras where in-line inspection is in scope, and a spectrophotometer feed for colour work. We survey the existing fleet first, most mills already have more sensing than they use.
Start with one agent
Most mills start with Dye-and-Color or Defect-and-Inspect, because that is where the money leaks fastest.
