Factory install runbook — Pereira

Physical-install runbook for the Pereira plant, executed in July 2026 by Sophia (likely with Armando and a local electrician). The plant is closed on Sundays — schedule install for a Sunday and keep an 8-hour window.

By the time this runbook runs, the LBZF Jetson is already pre-flashed and Tailscale-authenticated from California per ADR-006, and both Amcrest cameras have had their admin passwords set + P2P disabled during CA bench testing. Install day = physical mounting, cabling, and end-to-end verification only.

Goals

• G1. 2 Amcrest cameras mounted at Ronald’s chosen Angela workstations, IPs assigned per network-and-tailscale.md, both streaming RTSP to the Jetson.
• G2. Jetson powered, on the network, auto-reconnected to Tailscale, lbzf-monitor.service running, dashboard accessible at http://lbzf-jetson-01:5000 from a phone on cellular (over Tailscale).
• G3. Cable runs tidy, conduited where they cross walkways, labeled at both ends.
• G4. A local technical contact at LBZF trained on the 4 most common ops in Spanish.
• G5. Photographic record of every install location for future remote troubleshooting.

Non-goals

• First boot of the Jetson — done in CA per ADR-006 / jetson-edge-compute.md.
• Camera password setup + P2P disable — done in CA per network-and-tailscale.md. Cameras arrive in Pereira plug-and-play.
• Software changes — any required change during install is logged as a bug, not fixed in place.
• Phase II/III modules — Phase I = Angela only, 2 cameras.

Pre-arrival logistics (1 week before)

• Armando coordinates with Ronald to schedule a Sunday install window.
• Armando pre-buys the Colombia-side BOM at Homecenter Pereira: 1 box Cat6 UTP outdoor-rated (305m), J-hooks, conduit ~10m, drywall anchors / Tapcons (concrete factory walls), Velcro ties, RJ45 keystones + crimper + tester.
• Confirm electrician availability for a 110V outlet near the computer room if one doesn’t exist.
• Confirm Ronald is on-site that day — he picks which two workstations to instrument.

Tooling brought from CA

• Klein RJ45 crimper + ends + Cat6 tester
• Multimeter
• Cable labels + Sharpie + masking tape
• HDMI cable + Logitech MK120 keyboard for emergency local Jetson access
• Laptop on cellular hotspot for off-LAN Tailscale verification
• Phone with LBZF tailnet client installed
• Printed copy of this runbook + the IP plan from network-and-tailscale.md
• Argentina Type-I plug adapter (left over from BA leg — useful spare)
• 3–4 short Cat6 patch cables

Step 0 — Walk the floor with Ronald (30 min)

Walk the Angela module with Ronald and pick the 2 workstations to instrument first. Default criteria: highest SAM-variance stations (i.e., where cycle-time visibility delivers the most insight), or stations Ronald already suspects are bottlenecks.

For each chosen camera location:

1. Confirm the operation that runs there (from Ref22 Slim - Angela.xlsx, “Balanceo” tab).
2. Identify camera position. Default: ceiling- or wall-mounted, ~2.7–3.0 m height, angled 30–45° down so the camera sees both the operator’s torso and the work area (machine + fabric).
3. Note lighting interference — overhead fluorescent banks, sewing-machine LED task lights, windows.
4. Note cable run constraints — wall, conduit path, distance to the computer room.
5. Photograph the workstation from where the camera will sit. That photo is the placement spec.

The Amcrest IP8M-2779EW-AI has a varifocal 2.7–13.5mm lens (ADR-001) — focal length is set after mounting, so we’re not committed to a specific FoV until the lens is dialed in. This is the entire reason we picked a varifocal camera over a fixed-lens alternative. Use the live view from a laptop while adjusting the lens to verify operator hands + machine bed are visible at the corners.

Step 1 — Mount cameras (2–3 hours)

For each of the 2 cameras:

1. Mark the mount location per Step 0.
2. Drill anchor holes; install the mount bracket.
3. Run Cat6 from camera location to the computer-room TL-SG2210MP. Leave 1m service loop at each end.
4. Crimp Cat6 ends both sides; test with the cable tester before mounting the camera. A failed crimp is much easier to fix without a camera in the way.
5. Connect the camera to its Cat6, mount, point per the photo from Step 0.
6. Label the cable: CAM-01 at camera end, CAM-01 → P1 at switch end.

Lighting check at this step: plug in, look at live feed on a laptop. If auto-exposure is hunting (image visibly brightens/darkens every few seconds), the room has fluorescent flicker mismatched with the camera’s anti-flicker setting. Colombia is on 60Hz — set Amcrest’s anti-flicker to 60Hz; if 50Hz looks better visually, override and document.

Privacy posture: point the camera so its FoV captures the workstation and not the aisle behind it. Operators walking past should not be incidentally surveilled — the Confidencial — Uso Interno classification implies minimum-necessary collection.

Step 2 — TL-SG2210MP + Jetson (1 hour)

1. In the computer room, mount the TL-SG2210MP on a rack shelf or wall bracket. Not on the floor — sewing factory floors collect lint and clog intakes.
2. Plug both camera Cat6 runs into PoE+ ports 1 and 2.
3. Uplink: Cat6 from the existing plant LAN (Huawei GPON or downstream Archer C80) into port 10 (uplink port, visually distinct).
4. Place the Jetson (Waveshare Case A with PWM fan running) on a shelf with ≥10cm clearance on all sides. Not on top of the switch — heat radiating from the switch gets sucked into the Jetson intake.
5. Plug Jetson into port 3 of the TL-SG2210MP via Cat6.
6. Power the Jetson via the included 19V barrel-jack adapter. Not USB-C (jetson-edge-compute.md — community reports of brownouts over USB-C).
7. Power the TL-SG2210MP.
8. Verify Jetson boots: user-facing LED solid-green after ~60s. If HDMI + monitor available, plug in to watch the boot; otherwise wait 2 min then test SSH.

Step 3 — Network verification (30 min)

In order, do not skip:

1. From a laptop on the plant LAN: ping 192.168.1.10 (Jetson) → expect reply.
2. Ping each camera (192.168.1.21, 192.168.1.22) → expect reply. If a camera doesn’t reply, power-cycle it (unplug Cat6, wait 10s, replug). If still no reply, swap to the spare patch cable and re-crimp if needed.
3. SSH to the Jetson: ssh lbzf@192.168.1.10. Use key-based auth (the LBZF Jetson has Sophia’s and Andrew’s keys baked in from CA bring-up).
4. On the Jetson: tailscale status — expect lbzf-jetson-01 connected and the magicDNS name listed. Tailscale is configured pre-flight per ADR-005 and ADR-006.
5. From the cellular-hotspot laptop (NOT the plant LAN): ssh lbzf@lbzf-jetson-01 over Tailscale. If this fails, the deployment is not done — stop and debug Tailscale.
6. From cellular: open http://lbzf-jetson-01:5000 in a browser. Dashboard should load.

Step 4 — Capture pipeline verification (30 min)

On the Jetson, SSH’d:

1. systemctl status lbzf-monitor — expect active (running).
2. journalctl -u lbzf-monitor -n 200 --no-pager — expect to see lines like cam01: stream opened, cam02: stream opened, and no appsink: end-of-stream errors.
3. ls /data/video/cam01/ — expect a .mp4 file present and growing.
4. Open the dashboard from the cellular laptop. Both camera tiles show “live” with a recent timestamp.
5. With Ronald: have an operator at one instrumented station step away. Verify the dashboard registers a cycle-event boundary within ~5 seconds (inference is 3–5 fps per ADR-004, so up to ~2s of frame latency is expected before detection state flips).

Step 5 — Physical security (15 min)

1. Cable-tie the Jetson + switch so they can’t be unplugged accidentally.
2. Label the Jetson + switch with bilingual labels: LBZF CV — NO DESCONECTAR / DO NOT UNPLUG — Sophia +1-xxx-xxx.
3. Photograph the final install: rack-front, rack-back, each camera, the cable run path. Upload to Drive (LBZF Computer Vision Project / Photos and Videos / Install July 2026).

Step 6 — Hand-off training (30 min)

With the local technical contact (TBD with Ronald and Mariana), cover four scenarios in Spanish:

1. Cámara apagada (camera down) — walk to camera, check PoE LED on the TL-SG2210MP, replace Cat6 if necessary, call Sophia.
2. Jetson apagado (Jetson down) — power-cycle by unplugging 19V barrel for 10s; wait 90s; Sophia confirms Tailscale reconnect in the admin console.
3. Reiniciar servicio (restart service) — ssh lbzf@192.168.1.10 from the designated laptop → sudo systemctl restart lbzf-monitor. (Or wait for the cron health-check to do it automatically — see jetson-edge-compute.md § auto-recovery.)
4. Pedir ayuda (get help) — WhatsApp / Slack Sophia and Armando; both can SSH in via Tailscale.

Print a Spanish one-pager (rough draft prepared during the G1 gate) with these 4 steps + phone numbers + Tailscale URL. Tape it to the Jetson rack.

Step 7 — First Excel export (10 min)

Trigger the Excel export from the dashboard. Open the .xlsx; verify it matches the format Ronald is used to (INDICADORES ABRIL.xlsx shape). If anything looks wrong, log as a frontend bug, not an install bug.

Step 8 — Departure checklist

Before leaving the plant:

• Tailscale verified from cellular
• Both cameras streaming and recording
• First Excel export generated and approved by Ronald
• Local tech contact trained
• Photos uploaded to Drive
• Andrew + Armando notified install is complete

If any item fails, do not leave. Reschedule the flight if necessary; do not leave a partially-working install.

Environmental risks

• Lint / fabric dust. Sewing factory floors generate fabric dust that clogs intake fans. Mitigations: (1) put the Jetson in the air-conditioned office computer room (filtered upstream); (2) Waveshare PWM fan with low airflow + monthly compressed-air blow-out by the local tech.
• Power instability. Pereira shares the Colombian grid; outages happen. Phase I has no UPS in BOM — accepted risk for a 2-camera pilot. If brownouts prove routine post-deploy, add a UPS in Phase II.
• Theft. Cable-tie everything; the computer room is presumably access-controlled. Cameras mount high enough to discourage casual theft.
• Heat / humidity. Pereira is ~22°C year-round at 1,400m elevation, humidity 70–80%. Acceptable for the Jetson (with active cooling); Amcrest IP8M-2779EW-AI is IP67-rated.
• Cleaning chemicals. Don’t pressure-wash near the cameras; standard sewing-factory cleaning is fine.

Cross-bucket dependencies

• BOM (bom.md) — every part referenced here.
• Jetson spec (jetson-edge-compute.md) — Jetson arrives pre-flashed.
• Network spec (network-and-tailscale.md) — IP plan is the contract.
• Business bucket — confidentiality + worker-consent posture. Mariana owns operator-consent; if formal consent isn’t in place by July, install can still happen but dashboard access stays restricted to LBZF staff.

Rollout

1. 1 week pre-flight (early July) — Armando schedules the Sunday install with Ronald; pre-orders Colombia-side BOM.
2. 2 days pre-flight — final pack of CA-side hardware.
3. Travel day — Sophia + Armando depart for Pereira via Bogotá; Jetson + cameras in carry-on (do not check).
4. Install day (Sunday) — Steps 0–8.
5. Day after install — full shift runs with operators; Sophia + Ronald monitor remotely, log oddities.
6. 2 days post-install — Sophia departs; Ronald + the local tech contact have 24/7 Tailscale-accessible Sophia + Andrew.