Shadow mode first
Connectors and telemetry go in, models run against live production, and predictions are scored against what the mill actually made. Nothing is controlled.
Scenarios
Four scenarios, written before the results exist
These are the four deployments we expect to run first, written as scenarios so you can see what we would measure and how. None is a customer result. When a design partner signs off on numbers, the scenario becomes a case study on this page.
Design partners
Design partners wanted
We are onboarding three to five design partners on one wedge workflow each, in shadow mode first. No mill is named on this site until it has agreed to be.
Your baseline, not ours
Right-first-time, seconds, water and energy are measured against the mill’s own trailing twelve months before any claim is made.
A say in what gets built
Design partners set the first wedge, approve every autonomy step, and decide if and when their numbers are published.
Scenario · commission dyehouse, reactive exhaust jets
Holding shade first time at a commission dyehouse
The problem
A standing recipe card that assumes one substrate and one water profile, against a reality of many greige suppliers and seasonal hardness swings.
- Approach: Dye-and-Color runs in shadow against the standing card, then moves to assist mode with a colourist approval gate on any recipe deviating more than 5% from the card.
| Measure | How it is measured |
|---|---|
| Right-first-time shade | Lots on shade at first drain, against the dyehouse’s own trailing twelve months |
| Re-dyes | Re-dyes per hundred lots, before and after |
| Water per kg | Metered litres per kilogram of finished fabric, by shade family |
| Payback | Licence against avoided re-dye cost, from the mill’s own numbers |
Scenario · denim weaver and finisher, 148 cm
Catching defects in the machine on wide denim
| Measure | How it is measured |
|---|---|
| Defect escape rate | Defects found by the cutting room or the buyer per thousand metres |
| Grading disputes | Disputed rolls per week between inspection and cutting |
| Inspection labour | Hours of manual table inspection per shift |
| Seconds | Grade B share of output |
The problem
Manual inspection that cannot keep up with the finishing line, and graded rolls that the cutting room disputes every week.
- Approach: Defect-and-Inspect on line-scan vision at full line speed, with per-roll defect maps feeding the four-point grade automatically.
Scenario · knit dyehouse, many shade families
Taking water out of a knit dyehouse without new machines
The problem
Dye lots sequenced by whoever shouts loudest, so the plant pays for shade-family changeovers in water, steam and time.
- Approach: Yield-and-Takt sequencing with cuOpt under delivery, shade-family and machine constraints, plus utility allocation per lot.
| Measure | How it is measured |
|---|---|
| Water per kg | Metered litres per kilogram by shade family |
| Steam per lot | Metered steam per lot, normalised for weight |
| Changeovers | Shade-family changeovers per week |
| On-time ship | Lots shipped by the buyer date |
Scenario · technical textiles, buyer audited
A buyer audit packet in minutes instead of days
| Measure | How it is measured |
|---|---|
| Packet assembly | Hours from request to signed packet |
| Unlogged control actions | A count that must stay at zero |
| Non-conformance recurrence | Repeat findings per audit cycle |
| Audit findings | Open findings per audit |
The problem
Every buyer audit means a quality team reconstructing roll genealogy from spreadsheets, paper lab dips and machine logs.
- Approach: Quality-and-Conformance keeps immutable genealogy from bale to bolt, with test methods and chemistry declarations attached at release.
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
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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.
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.
Design-partner programme
What a design partnership involves
Three to five mills, one wedge workflow each, shadow mode first. The sequence comes from our MVP plan and does not change for anyone.
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Phase 1
Instrument
The wedge workflow is connected in shadow mode and the baseline for seconds, re-dyes and waste is measured from the mill’s own data.
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Phase 2
Assist
The agent recommends yarn, construction and recipe moves and predicts defects and shade. An engineer approves each one, and accuracy is scored in the open.
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Phase 3
Graduate
Low-risk inspection, dye and finishing loops move to bounded auto-control one setpoint at a time. Exceptions escalate to a named person.
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Phase 4
Expand
Adjacent modules are added within the same mill once the wedge holds its numbers. Publication of results is the mill’s decision.
Deployment
From first connector to bounded control, one phase at a time
No mill hands over a jet on day one. The path is deliberately slow at the start and faster once the numbers hold. Durations are quoted after the assessment, because they depend on how instrumented the mill already is.
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Phase 1
Connect
Mill survey, edge appliance install, connectors to machines, MES and meters. Telemetry starts flowing; nothing is controlled.
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Phase 2
Observe
Models run in shadow against live production. Predictions are scored against what the mill actually produced, on your data.
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Phase 3
Assist
The agent proposes; a human commits. Approval gates, setpoint envelopes and revert paths are agreed with the process owners.
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Phase 4
Control
Bounded auto-control on the setpoints you authorise, one at a time, with autonomy ceilings that you can lower at any moment.
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.
Pricing
Land on one line. Expand across the mill.
Priced per line, per mill or per group, with outcome-based components on the workflows where the value is measurable.
Line
Mills validating ROI on a single wedge workflow.
- One agent workflow on one line, yarn/fabric control, dyeing, or inspection
- Mill-edge inference appliance and connector for that line
- Run timeline, tool-call log and immutable audit trail
- Assist mode with human approval on every control action
- Standard email and shared-channel support, 1 business-day response
Mill
Full loopScaling mills adopting the full perceive–decide–act loop.
- All nine agents: spin, weave/knit, dye, finish, defect, shade, yield/takt, robotics, conformance
- As-produced fabric digital twin with pre-run simulation
- Graduated autonomy with per-workflow approval policies and spend limits
- Mill-edge fleet management and offline fallback control
- Roll genealogy, buyer conformance packets and sustainability reporting
- Named mill engineer and quarterly outcome review
Enterprise
Integrated textile groups standardising on Yarneon.
- Multi-site deployment with group-level benchmarking
- Custom fibre, construction and shade models trained on your archive
- On-prem or private-VPC deployment via NVIDIA AI Enterprise
- SSO, SCIM, RBAC, data residency and signed SLAs
- Outcome-based commercial components on yield, seconds, re-dyes and utilities
- Dedicated solutions team and 24×7 support
Annual prepay saves 15 to 20% depending on term. Full detail, including outcome-based terms, on the pricing page.
Your mill, your baseline
Shadow mode scores our predictions against what you actually produced, before you grant a single setpoint.
