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projects/isogrid-dev-plate/playbooks/01_FIRST_RUN.md

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+# Playbook 01 — First Run: Campaign 01 (TPE v1)
+
+**Study:** `studies/01_v1_tpe`
+**Algorithm:** Optuna TPE, 200 trials
+**Constraint:** Stress only — σ_max ≤ 100.6 MPa (no displacement constraint)
+**Expected runtime:** ~8–10 hours
+
+---
+
+## Pre-conditions
+
+Before starting, verify:
+- [ ] NX DesigncenterNX2512 is installed
+- [ ] `atomizer` conda environment is active
+- [ ] You are running from the `Atomizer/` root directory
+- [ ] NX files in `studies/01_v1_tpe/1_setup/model/` (check with step 1)
+
+---
+
+## Step 1 — Pre-flight Check
+
+Run the pre-flight script to verify all files, imports, and NX are ready:
+
+```bash
+C:\Users\antoi\anaconda3\envs\atomizer\python.exe \
+  projects/isogrid-dev-plate/studies/01_v1_tpe/check_preflight.py
+```
+
+Expected output:
+```
+Pre-flight checks
+============================================================
+
+Model files:
+  [OK]      Geometry part (X.X MB)
+  [OK]      Idealized part (CRITICAL) (X.X MB)
+  [OK]      FEM file (X.X MB)
+  [OK]      Simulation file (X.X MB)
+  [OK]      Sandbox 1 geometry (X.X MB)
+  [OK]      Sandbox 2 geometry (X.X MB)
+
+NX:
+  [OK]      run_journal.exe: C:/Program Files/Siemens/DesigncenterNX2512/NXBIN/run_journal.exe
+
+Python Brain:
+  [OK]      optimization_engine.isogrid
+            Material: AL7075-T6  sigma_allow=100.6 MPa
+
+Extractors:
+  [OK]      extract_part_mass_material + extract_solid_stress
+
+============================================================
+All checks PASSED — ready to run run_optimization.py
+```
+
+If anything is `[MISSING]`, resolve before continuing.
+
+---
+
+## Step 2 — Launch Campaign 01
+
+```bash
+C:\Users\antoi\anaconda3\envs\atomizer\python.exe \
+  projects/isogrid-dev-plate/studies/01_v1_tpe/run_optimization.py
+```
+
+The script will print a header:
+```
+======================================================================
+  Isogrid Dev Plate — Mass Minimization Study 01 (TPE v1)
+======================================================================
+  Material:    AL7075-T6
+  σ_yield:     503.0 MPa
+  σ_allow:     100.6 MPa  (SF = 5)
+  Trials:      200
+  DB:          ...3_results/study.db
+```
+
+Then iterate:
+```
+--- Trial 0 ---
+  η₀=0.123  α=0.875  β=0.412  γ_s=0.234  R₀=45.2  R_e=18.7  s_min=12.3  s_max=41.5
+  [Brain] sandbox_1: 104 pockets  valid=True  mass_est≈2420g
+  [Brain] sandbox_2: 31 pockets   valid=True  mass_est≈310g
+  [Brain] Total pockets: 135
+  [NX] Running journal: import_profile.py
+  [NX] OK in 18.3s
+  [NX] Running journal: solve_simulation.py
+  [NX] OK in 74.2s
+  [Extract] Mass: 2.731 kg  (2731.0 g)
+  [Extract] Max stress: 83.47 MPa  (allow=100.6  SF=6.02)
+  [Obj] mass=2.7310 kg  penalty=0.00  obj=2.7310  feasible=True
+```
+
+---
+
+## Step 3 — Monitor Progress
+
+### Option A: Console output
+Watch the terminal. Each trial prints mass, stress, and objective.
+
+### Option B: Optuna dashboard
+```bash
+C:\Users\antoi\anaconda3\envs\atomizer\python.exe -m optuna-dashboard \
+  sqlite:///projects/isogrid-dev-plate/studies/01_v1_tpe/3_results/study.db
+```
+Then open http://localhost:8080 in a browser.
+
+### Option C: Trial folders
+Each completed trial creates:
+```
+studies/01_v1_tpe/2_iterations/trial_NNNN/
+├── params.json          ← sampled design variables
+├── results.json         ← mass, stress, SF, objective
+├── rib_profile_sandbox_1.json   ← rib geometry for this trial
+└── rib_profile_sandbox_2.json
+```
+
+---
+
+## Step 4 — If a Trial Fails
+
+Failures return a large penalty (`1e6`) and are logged in Optuna with `error` user attribute.
+The study will **continue automatically** to the next trial.
+
+To see which trials failed after the run:
+```python
+import optuna
+study = optuna.load_study(
+    study_name="isogrid_01_v1_tpe",
+    storage="sqlite:///studies/01_v1_tpe/3_results/study.db"
+)
+failed = [t for t in study.trials if t.user_attrs.get("error")]
+for t in failed:
+    print(f"Trial {t.number}: {t.user_attrs['error']}")
+```
+
+---
+
+## Step 5 — Resume After Interruption
+
+The optimizer uses `load_if_exists=True` — it resumes from where it stopped.
+Simply re-run the same command:
+
+```bash
+C:\Users\antoi\anaconda3\envs\atomizer\python.exe \
+  projects/isogrid-dev-plate/studies/01_v1_tpe/run_optimization.py
+```
+
+It will print:
+```
+Resuming study: N trials already complete.
+Current best: trial X  obj=2.XXXX kg  mass=2.XXXX kg  SF=X.XX
+```
+
+---
+
+## Step 6 — After the Run
+
+1. **Fill in `STUDY_REPORT.md`** with actual results:
+   - Best trial number, mass, stress, SF
+   - Convergence trial (when best was found)
+   - Feasibility rate
+
+2. **Update `CONTEXT.md` baseline mass** (Gap G-02):
+   - Run `extract_part_mass_material` on the unmodified model to get solid plate baseline
+
+3. **Record improvement:**
+   - `mass_reduction = (baseline_mass - best_mass) / baseline_mass * 100`
+
+4. **Archive if campaign is complete:**
+   ```bash
+   python tools/archive_study.bat  # or zip 3_results/ manually
+   ```
+
+---
+
+## Troubleshooting
+
+| Symptom | Likely Cause | Fix |
+|---------|-------------|-----|
+| `[NX] FAILED` on import journal | NX can't find model files | Check `1_setup/model/` has all 4 NX files |
+| Identical stress every trial | `_i.prt` not loading | Verify `ACS_Stack_Main_Plate_Iso_project_fem2_i.prt` exists in model dir |
+| `Brain ERROR` | Geometry JSON malformed | Check `geometry_sandbox_1.json` / `_2.json` in `adaptive_isogrid_data/` |
+| `run_journal.exe not found` | Wrong NX version path | Confirm DesigncenterNX2512 is installed; check `check_preflight.py` |
+| Very high stress (>500 MPa) | Mesh not updating | `_i.prt` must be in same directory as `.fem` |
+| Trial folders not appearing | `2_iterations/` not created | Should auto-create; check for TrialManager error in console |
+
+See also: `docs/protocols/operations/OP_06_TROUBLESHOOT.md`