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Author: Livia In-Albon

SBB FLIRT EVO – Factory Acceptance Tests (FAT): Test specification interior & exterior indicators

Customer: Stadler Bussnang AG, Switzerland

Project tasks

  • Define software interface test matrix
  • Check interface documents
  • Carrying out laboratory and vehicle tests
  • Logging of the test execution
  • Final discussion and definition of the next steps

Our approach

Stadler has been commissioned by the Swiss Federal Railways (SBB) to supply the new FLIRT fleet. An important part of the project is the integration of various passenger information system components, including LED and TFT displays, into the APFZ 2.0 system developed by SBB. During the course of the project, however, problems arose with the interface integration of Stadler’s supplier for the display technology, which were only discovered relatively late. These challenges led to functional faults in the vehicles.

As Stadler had limited resources at its disposal, PROSE was commissioned to gain an overview of the situation within a very short space of time. PROSE was tasked with checking the specifics and developing a comprehensive test script and test matrix with the help of information from Stadler and SBB. The aim was to quickly identify the exact causes of the problems that had arisen by carrying out tests in the laboratory and directly on the vehicles.

Customer benefit

By working with PROSE, the customer benefits from extensive expertise in software development as well as interface and protocol management. With PROSE’s support, the problems encountered could be analysed in a structured manner and their causes investigated by means of carefully planned tests. Stadler, SBB and the supplier of the displays all benefited from this expertise and came much closer to solving the technical difficulties.

 

    

Design and approval strategy for a rail-bound maintenance machine

Customer: SCHÖMA, Germany

Project tasks

  • Vehicle authoirsation strategy
  • Design assurance (Systems Engineering)
  • Concept development
  • Technical evaluation of offers and technical coordination with suppliers
  • Project management

Our approach

SCHÖMA plans to develop a proven, powered, three-part rail-bound maintenance machine with cab, loading platform and crane called HERO. SCHÖMA needs support in developing the authorisation strategy to fulfil the EN 14033 standards and in defining the design process including verification and validation.

PROSE developed the decision-making basis for the approval process enabling a defined combination of the three vehicles of the working machine to be approved and the verifications and evidence according to EN 14033 to be provided. PROSE also supported SCHÖMA in the budget planning phase of the development of the HERO work machine in the evaluation of supplier offers for systems and components such as the power train, braking system, power generation, train protection (ETCS) and heating, ventilation and air conditioning (HVAC). In addition, PROSE defined the design phases and the design assurance process according to the systems engineering methodology to ensure a defined and structured design process.

Customer benefit

​PROSE has structured and optimised SCHÖMA’s development process by systematically applying the system engineering methodology. This approach has not only minimised development risks associated with costs and timelines but has crucially enhanced the predictability and likelihood of obtaining necessary approvals from authorities.

 

          

Digitalisation of maintenance requirements

Customer: SBB Historic, Switzerland

Project tasks

  • Research: Review and analysis of the existing documentation (e.g., old regulations)
  • Expert Interviews: Enrichment of the database with know-how from specialists
  • Documentation: Creation of maintenance plans for the 14 rail vehicles and 3-4 wagon fleets
  • Approval: Incorporation of client feedback and final adjustments

Framework conditions:

  • Utilisation of old regulations as the basis
  • Supplementation through reverse engineering and other methods to address data gaps
  • Collaboration with the client, particularly in providing knowledge and feedback

Our approach

The project was initiated by SBB Historic to gradually align the existing maintenance organisation and fleet management with European standards. The core challenge lies in transforming a fragmented documentation base. Many of the historic vehicles have only partially available operational and maintenance manuals, as the original manufacturers either no longer exist or the documentation has been lost over time.

Additionally, the introduction of the ZEDAS maintenance software is intended to support and future-proof the maintenance processes. The project aims to create a consistent and standard-compliant maintenance plan landscape for the historic rail vehicles, enabling efficient, safe, and resource-conscious maintenance. At the same time, the transition will ensure compliance with European norms and facilitate maintenance activities carried out by in-house teams, associations, and third parties.

To achieve these objectives, PROSE adopts a structured approach comprising several interconnected work steps. The process begins with extensive research, focusing on reviewing and analysing old maintenance regulations to compile and prepare existing content. Subsequently, PROSE conducts expert interviews to incorporate historical knowledge from specialists, fill existing gaps, or update outdated guidelines. Based on this, maintenance plans are developed for the 14 rail vehicles and three to four wagon fleets. These plans are created iteratively, incorporating client feedback to ensure a tailored solution. Finally, the plans are integrated into the new maintenance concept and adapted to the requirements of the ZEDAS software.

The PROSE team, consisting of experienced experts, guarantees a professional and quality-orientated implementation. If necessary, the team is supported by other experts to ensure the quality and efficiency of the implementation.

Customer benefit

The project provides the client with numerous advantages that go beyond merely developing maintenance plans. By establishing a consistent, standards-compliant planning framework, the maintenance of historic vehicles can be carried out safely, efficiently, and cost-effectively. The integration of existing regulations and the supplementation of missing content through expert interviews not only reduces time and financial expenditure but also ensures that the plans are highly practical and relevant.

Another significant benefit lies in the introduction of the ZEDAS maintenance software, a key component for future digitalisation and optimisation of processes. The combination of technical and operational expertise provided by PROSE ensures that the plans are seamlessly integrated into the new software ecosystem, creating a high level of efficiency and transparency.

With transparent pricing and an agreed cost ceiling, the project remains financially predictable and manageable. At the same time, SBB Historic and the participating organisations benefit from PROSE’s extensive experience and proven competence. PROSE delivers tailored and sustainable solutions in the railway sector. The outcome is not only technically flawless but also an economically viable solution that guarantees the long-term safe operation of the historic fleet.

 

 

General Contract of Use for freight wagons (GCU) in Railway Undertakings (RU)

Customer: SBB Cargo, Switzerland

Project tasks

  • Analyse the current state, identify weaknesses and strengths, and document responsibilities and workflows
  • Develop a target model with clear responsibilities, efficient processes, and the use of new digital tools such as the GCU-Broker
  • Implement the new processes, including employee training and the establishment of overarching responsibility for GCU

Our Approach

The project to optimise the GCU (General Contract of Use for freight wagons) tasks within SBB Cargo’s RU (Railway Undertaking) role addressed the growing demands of European freight transport and the increasing expectations for legal and process compliance. The primary goal was to establish a clear and robust organisation of responsibilities within the RU role, meeting both the requirements of the GCU and relevant EU regulations. This realignment was achieved through a systematic review of existing processes and structures. Key challenges included the precise delineation of roles between the railway undertaking and the wagon keeper, as defined by the GCU provisions. In particular, the requirements arising from oversight by the Swiss Federal Office of Transport (FOT) necessitated reorganisation, as unclear responsibilities had previously hindered audit outcomes.

Additionally, action was required for key operational processes such as the re-commissioning of freight wagons after repairs, the verification of GCU-compliant wagons within train formations, and the retrieval of technical wagon data from third-party keepers. These areas are critical for ensuring safety and quality standards. At the same time, the entire scope of GCU tasks is subject to increasing regulation, which will be further intensified by the BAV (Federal Office of Transport in Switzerland) from 2026 onwards. To meet these demands, SBB Cargo’s internal processes must not only become more efficient but also legally sound.

The project was implemented in multiple phases. In the first phase, the current state of GCU tasks was documented, and key strengths and weaknesses were identified. This analysis was completed by May 2024. Building on this, by August 2024, a target process was developed that defines clear responsibilities, optimises existing workflows and incorporates digital solutions such as the GCU-Broker. This tool is intended to replace the manual processing of damage reports, thereby modernising data exchange. Starting in January 2025, the target process will be implemented, with a focus on appointing a central overall responsibility for GCU tasks, covering both strategic and operational duties. The project team included PROSE internal experts and external consultants from BAHNVERSTAND, who provided methodological support and strategic recommendations.

Customer benefit

​The implementation of the project delivers significant benefits for customers through more efficient and reliable handling of GCU tasks. Clear responsibilities and improved processes reduce delays and enhance legal certainty in operations. The integration of digital solutions, such as the GCU-Broker, lowers administrative costs and accelerates data exchange. Furthermore, compliance with new legal requirements, particularly EU and FOT regulations, ensures long-term legal security and minimises liability risks. Overall, the project strengthens SBB Cargo’s position in the European freight transport market and ensures sustainable future viability.

 

3rd party assessment of exterior camera installation

Customer: MTR Tech, Sweden

Project tasks

  • Assessment of proposed and installed solutions of camera installation
  • Highlighting risks and deviations from industry standards and recommendations

Our Approach

MTR has operated and maintained the X60 Coradia fleet on behalf of the Stockholm Region until 2024. The region has ordered installation of cameras from Alstom to support the drivers and improve visibility around the door-area, particularly on platforms with curved tracks.

PROSE has extensive experience in mechanical and electrical design as well as design processes, especially in adhesive bonding. Based on our expertise, an iterative assessment process has taken place to assess the proposed and installed solution. It includes recommendations in line with industry best practice for both mechanical design and bonding – as well as design and processes – in accordance with EN17460.

Customer benefit

​Adding additional equipment to an existing fleet without impacting the basic design requires experience and know-how about production methods and the original design. With PROSE as an independent assessor, the client received an independent assessment of the proposed and installed solution as well as the identification of potential short- and long-term risks in the proposed design of both the bonded joints and the mechanical parts.

 

      

Highlights of the joint workshop at Borflex-Rex SA in Mendrisio

Our PROSE team recently had the opportunity to take part in a comprehensive workshop at Borflex-Rex SA in Mendrisio. Led by Claudio Rossi, Bernardo Moltrasio, Salvatore Basso and Gennaro Mauro, the workshop gave our experts an in-depth insight into the design and manufacture of rubber-metal parts. 

These components, from sleeper pads and rubber springs to door seals, are important for improving comfort and sustainability in railway systems. We are grateful for sharing knowledge and experiences at the event. It shows how much we value expertise and reliability at PROSE.

We would also like to thank SUPSI (University of Applied Sciences of Southern Switzerland) for presenting their innovative work at the Dipartimento Tecnologie Innovative.

This workshop is just one of many steps we are taking together to promote railway technology and ensure a more comfortable and sustainable future in mobility. 

A Glimpse into PROSE’s Engineering Day Highlights

At PROSE, we believe that building strong, collaborative teams is key to delivering great value to our customers. Our teamwork ensures that we bring the best of our collective skills to every project, improving the quality and reliability of our solutions.

In November, we showed our dedication to innovation in railway technology during our two-day event, Engineering Day. Our teams focused on important topics that are fundamental to improving project outcomes and customer satisfaction.

Key Topics Covered:

  • Basic signalling: Discussed the importance of signalling for safety and efficiency in railway operations.
  • Alternative drive systems: Highlighted progress towards sustainable solutions and their impact on future rail vehicles.
  • Vehicle Authorisation – Maintenance vs. Modification: Covered key points for navigating regulatory frameworks in vehicle engineering.
  • ETCS Onboard Units: Looked at the latest advancements in ETCS technology and its role in improving rail transport safety and efficiency.

By fostering a collaborative environment, we ensure that each team member contributes to and benefits from the collective knowledge and skills. This approach not only improves our internal capabilities but also translates into better service and innovative solutions for our customers, we call it the “prose.one-approach”.

Join us on this journey as we continue shaping tomorrow’s mobility https://prose.one/

Program Management ATO Sector Program

Customer: BLS Netz AG, Dr. Florian Kappler, Switzerland

Project tasks

  • Program Management
  • Project Planning
  • Coordination among all Swiss ATO projects
  • Leading the marketing team to develop and maintain the ATO website
  • Quarterly reporting to the steering board (railway undertakings, infrastructure managers and industry)
  • Coordination with stakeholders, such as the national authority BAV, as well as the industry
  • Supporting specific ATO projects with technical-, operational- and business advisory

Our Approach

In May 2022, the Federal Office of Transport called on the rail sector to align and better coordinate future ATO activities within the Swiss rail sector.

PROSE was commissioned to manage the programme for all Swiss ATO projects. In close cooperation with the ATO core team, PROSE established regular monthly exchanges and jointly identified and developed central cross-cutting topics.

In addition, PROSE also led the communication team and worked with this team to develop and maintain the ATO industry website (https://voev.ch/ato). Furthermore, PROSE initiated an ATO-related conference day that invited and actively involved the industry in ATO developments.

Customer benefit

With PROSE as a partner, the customer benefits from comprehensive expertise in the areas of on-board signalling, ETCS and ATO, both on the line and on the vehicle side. An entrepreneurial approach, in-depth technical knowledge and market knowledge are essential for a successful programme design in the first year.

The customer does not need to develop its own project-specific management resources, as PROSE, as an independent consultant, coordinates the related interests of all project managers.

 

   

How PROSE solves the “Old depot, new fleet?” dilemma

Last week, we had the opportunity to share our expertise at the IHRUS conference. PROSE employee Tobias Hoppe shed light on the complex interplay between existing depots and new fleet orders and showed how innovative approaches can create solutions. 

Here are the three most important take-home messages from his presentation:   

  • Mastering challenges: Flexibility and innovative adaptations are the key to making old workshops fit for new requirements.   
  • Involve employees: On-site knowledge and precise simulations lay the foundation for successful planning.   
  • Shaping the future: Automation and flexibility ensure efficient and sustainable workshop concepts for tomorrow.   

Many thanks to all participants for the inspiring exchange! Together we are shaping the future of railway technology.  

Get in touch with us to find out how our expertise can help you in shaping tomorrow’s railway maintenance: https://prose.one/contact/ 

Big news for our German market!

Thanks to our extensive experience in production, acceptance, commissioning and maintenance, PROSE was commissioned as an expert for the new electric multiple units (EMU) on the MoselLux network by the Rhineland-Palatinate North Rail Transport Association (SPNV-Nord) and the Saarland Ministry of the Environment, Climate, Mobility, Agriculture and Consumer Protection.

In this multi-year contract, we are supporting the 19 Flirt EMUs ordered and ensuring that all requirements are implemented correctly. We are particularly proud of the task entrusted to us, in which we support the reuse guarantee of the regional rail transport contract and promote sustainable mobility in the region.

Find out more about our projects and services on our website and contact us if you have any questions about consulting or cooperation: https://prose.one/contact/

Image source: https://commons.wikimedia.org/wiki/File:Hangviadukt_P%C3%BCnderich-Moselle_River_in_P%C3%BCnderich._2H1A3194WI.jpg

Working together to innovate and shape the future of rail freight

With the LEILA Light bogie, developed in collaboration between JOSEF MEYER Rail and PROSE, we are setting new standards in rail freight transport. The joint venture stands for efficiency, sustainability and technical excellence: LEILA Light reduces noise and minimises wear and tear on the rail infrastructure, resulting in significant cost advantages and increased speed.  

But such innovations require more than just technology. Cooperation and targeted use of resources are crucial to overcoming challenges such as the asymmetrical distribution of the costs of technologies and jointly paving the way for the future. 

Find out more about our developments here (only in German): https://cargorail.ch/die-asymmetrie-von-vorteilen-und-umsetzungskosten-erachte-ich-als-groessten-knackpunkt-der-dak/ 

‘Digitalisation – but the right way!’ – PROSE at the Siegburg exchange of experience on locomotive maintenance

Next week, the specialist conference on locomotive maintenance will take place in Siegburg – a central industry meeting point for manufacturers, system providers, rental companies, railway operators and workshops. The main topic this time is ‘Digitalisation – but the right way!’. The focus is on how digital technologies can be meaningfully integrated into maintenance processes in order to increase efficiency and safety.

PROSE is proud to be actively involved – among other things with a presentation by Dr Bernhard Frei, Director Corporate Development at PROSE. He will talk about successful ECM approaches for historic vehicles.

PROSE is pleased to participate in this event, where practical best practice examples will be shared and solutions for collaboration will be developed. With a structured exchange of experiences and topics such as bar camp sessions, the conference promotes networking and provides valuable insights into the future direction of the industry.

Interested? Buy your ticket here: https://www.bahnverstand.ch/veranstaltungen-von-bahnverstand/lok-ihi-2024/

info@prose.one

 

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